REMY TECHNOLOGIES, L.L.C. Patent applications |
Patent application number | Title | Published |
20150346036 | MOUNTING ARRANGEMENT FOR A TEMPERATURE SENSOR IN AN ELECTRIC MACHINE - An arrangement for sensing temperature in an electric machine comprises a plate member including a first side, a second side, a perimeter portion, and at least one hole extending through the plate member from the first side to the second side. A mount is coupled to the plate member. The mount includes a retention surface, at least one first arm, and at least one second arm. The retention surface is removed from the first side of the plate member. The at least one first arm extends from the retention surface and engages the perimeter portion of the plate member. The at least one second arm extends from the retention surface and through the at least one hole of the plate member. A temperature sensor is positioned between the first side of the plate member and the retention surface of the mount. | 12-03-2015 |
20150295480 | ELECTRIC MACHINE WITH COMBINED INSULATOR AND TERMINAL ASSEMBLY - An electronics package for an alternator includes an electrically conductive carrier member and a terminal assembly engaging the carrier member. The carrier member includes an inner side, an outer side, and at least one passage extending from the inner side to the outer side. A plurality of switches are connected to the carrier member. The terminal assembly includes an electrically insulative portion and a plurality of electrical traces extending through the electrically insulative portion. The electrically insulative portion includes a post extending through the at least one passage of the carrier member, a first shoulder engaging the outer side of the carrier member, and a second shoulder engaging the inner side of the carrier member. The post, the first shoulder, and second shoulder are all formed as a unitary component. | 10-15-2015 |
20150288242 | CONDUCTOR RETENTION MEMBER FOR A STATOR ASSEMBLY - A conductor retention member for a stator core includes a body formed from a non-electrically conductive material. The body includes a radial outwardly facing edge and a radial inwardly facing edge. A plurality of openings extends between the radial inwardly facing edge and the radial outwardly facing edge formed in the body. The body is configured and disposed to be arranged at an axial end of the stator core with the plurality of openings registering with corresponding ones of a plurality of stator slots. | 10-08-2015 |
20150285204 | INTERNAL COMBUSTION ENGINE HAVING A CHANGE OF MIND (COM) STARTER SYSTEM AND A COM STARTER SYSTEM - An internal combustion engine includes a ring gear, a speed sensor operatively associated with the ring gear, and a change of mind (COM) starter motor mechanically linked to the internal combustion engine. The COM starter motor includes an armature and a pinion operatively connected to the armature. A solenoid is operatively connected to the COM starter motor. The solenoid selectively moves the pinion into engagement with the ring gear. An electronic control unit (ECU) is operatively connected to the speed sensor and the solenoid. The ECU is configured and disposed to indirectly detect a rotational speed of the pinion and selectively energize the solenoid to axially shift the pinion into engagement with the ring gear when the pinion reaches a particular rotational speed relative to a rotational speed of the ring gear. | 10-08-2015 |
20150280526 | ELECTRIC MACHINE WITH HEAT TRANSFER ENHANCER - An electric machine includes a core defining a first axial end, a second axial end opposite the first axial end, and a plurality of slots extending between the first axial end and the second axial end. Windings are wound on the core. The windings include in-slot portions positioned in the plurality of slots and end turn portions positioned on the first axial end and the second axial end. A cooling tube is coupled to the end turn portions of the windings. A heat transfer member extends between the cooling tube and the windings and is in contact with the cooling tube and the windings. | 10-01-2015 |
20150275836 | STARTER MOTOR INCLUDING A REMOVABLE SOLENOID TOWER - An electric machine includes a housing having an outer surface and an inner surface defining an interior zone. A solenoid mounting section is provided on the housing. The solenoid mounting section includes a shift lever opening that extends from the outer surface through the inner surface. A solenoid tower is mounted to the housing. The solenoid tower extends from a first end detachably coupled to the solenoid mounting section to a second end configured to receive a solenoid. The first end includes an opening that registers with the shift lever opening. At least one of the solenoid mounting section and the solenoid tower includes a seal. | 10-01-2015 |
20150244230 | ALTERNATOR INCLUDING A STATOR CORE WITH SLOT LINERS - A stator core includes a plurality of stator teeth. The plurality of stator teeth defines a plurality of slots. Each of the plurality of slots includes a first side, a second side, and a base joining the first and second sides. A slot liner is arranged in at least one of the plurality of slots. The slot liner includes a first side portion, a second side portion, and a base portion. The first side portion extends from a first end to a second end joining the base portion through a first intermediate portion. The second side portion extends from a first end to a second end joining the base portion through a second intermediate portion. A bend is formed in the first intermediate portion. The bend creates a gap between the first side portion and the first side. | 08-27-2015 |
20150244129 | ALTERNATOR BRUSH HOLDER - A brush holder assembly for an alternator having a rotational axis includes a pair of brushes each having a contacting surface defining a width and a height, and each having a shunt wire extending laterally from the brush in the widthwise direction. The brush holder assembly includes a housing having first and second brush chambers, corresponding first and second wire cavities each defining a cavity height, and first and second slots respectively interposed between the corresponding chamber and cavity. The respective shunt wires extend through the first and second slots then through the first and second wire cavities. The cavity heights are each at least approximately 0.9 times the height of one of the brushes. The height of the first wire cavity is less than approximately 0.97 times ((A/2) plus B), wherein A is the brush height and B is the distance between the brushes. | 08-27-2015 |
20150107728 | METHOD FOR FORMING AND ANNEALING AN INSULATED CONDUCTOR - A method of forming an insulated conductor, includes forming an insulated conductor to modify a cross sectional shape thereof Heating at least a portion of the insulated conductor to a selected temperature range. Maintaining the selected temperature range for at least a selected period of time thereby annealing the conductor. Forming the insulated conductor into a plurality of gable shaped loops; and maintaining insulating properties of an insulation layer of the insulated conductor. Also included is a method of annealing an insulated conductor, | 04-23-2015 |
20150069884 | COMPONENT FOR AN ELECTRIC MACHINE - An electric machine component includes a rotor assembly having at least one claw pole member having a number of pole members, an outer fan member support surface, and a central hub projecting from the outer fan member support surface. The central hub includes an anti-rotation member and a substantially planar bearing surface. | 03-12-2015 |
20150069883 | COMPONENT FOR AN FOR AN ELECTRIC MACHINE - An electric machine component includes a rotor assembly having a body provided with a number of pole members and a central hub. The body includes at least one mounting member projecting radially outwardly of the central hub. A fan member is mounted to the rotor. The fan member includes a hub portion and a number of fan blades projecting radially outwardly from the hub portion. The fan member includes at least one mounting element extending radially outwardly of the hub portion. The at least one mounting element is configured and disposed to engage with the at least one mounting member to radially and axially constrain the fan member to the rotor. | 03-12-2015 |
20150057121 | Planetary Gear Assembly of a Starter Motor - A starter motor for an engine includes a housing and a planetary gear assembly. The housing defines an interior space. The planetary gear assembly is at least partially positioned in the interior space and includes (i) a sun gear having a first number of gear teeth equal to a pitch diameter of the sun gear, (ii) a ring gear having a second number of gear teeth equal to a pitch diameter of the ring gear, and (iii) no more than two planet gears each connected to a planetary gear carrier. Each planet gear of the no more than two planet gears has a third number of gear teeth equal to a pitch diameter of the no more than two planet gears. | 02-26-2015 |
20150054374 | DISTRIBUTED CASCADED WINDING FOR ELECTRIC MACHINES - A stator includes a cylindrical core with a plurality of longitudinally extending slots, a first winding set formed as a first cascaded wire in two radial layers of the slots, a second winding set formed as a second cascaded wire in two other radial layers of the slots, and a jumper connecting the first and second wires. A first winding set may have three cascaded phase wires in first and second layers of the slots, and a second winding set may have three cascaded phase wires in third and fourth layers of the slots. A winding set of a first phase may have a first cascaded wire in two radial layers of a first one of the slots, and a winding set of a second phase may have a second cascaded wire in two other radial layers of the first one of the slots. | 02-26-2015 |
20150028716 | INSULATION COMPONENT FOR AN ELECTRIC MACHINE AND METHOD OF ASSEMBLY - An electric machine includes a core with a plurality of teeth that extends between end faces of the core. Slots are defined in the core between adjacent teeth of the plurality of teeth. The slots each have a radial opening formed between end portions of the adjacent teeth. An insulation sheet is positioned on the core to obstruct the radial openings to the slots. The insulation has at least two spaced circumferential members that respectively overlap the end faces of the core. The insulation sheet also has a plurality of spaced axial members connected to the circumferential members. The axial members are positioned within the slots to obstruct the radial openings to the slots. | 01-29-2015 |
20150008773 | ALTERNATOR INCLUDING ELECTRICAL CONNECTOR ASSEMBLY - An electrical machine includes a voltage regulator, a rectifier, a first terminal structure, and a second terminal structure. The voltage regulator includes a first electrical lead. The rectifier includes a second electrical lead. The first terminal structure extends from the first electrical lead and defines a receptacle opening. The first terminal structure includes (i) a first prong configured to at least partially occlude the receptacle opening, and (ii) a second prong configured to at least partially occlude the receptacle opening. The second terminal structure extends from the second electrical lead. The second terminal structure extends through the receptacle opening and defines a first connection surface against which the first prong is positioned, and an opposite second connection surface against which the second prong is positioned. The first terminal structure and the second terminal structure mechanically connect and electrically connect the first electrical lead to the second electrical lead. | 01-08-2015 |
20140339964 | ALTERNATOR FAN - An alternator fan includes a base member having a central hub, an outer peripheral edge, and a web that extends between the central hub and the outer peripheral edge, and a plurality of openings extending through web. A plurality of fan blade elements is arranged in corresponding ones of each of the plurality of openings. | 11-20-2014 |
20140339933 | ELECTRIC MACHINE INCLUDING AN ADAPTABLE COOLING SYSTEM - An electric machine includes a housing having an outer surface and an inner surface. A stator is fixedly mounted to the inner surface. The stator includes a stator core, and a plurality of windings supported by the stator core. The plurality of windings includes first and second end turn portions. A rotor is rotatably mounted within the housing. An adaptable cooling system is fluidically connected to the housing. The adaptable cooling system includes a first coolant circuit configured to guide coolant in a heat exchange relationship with the stator core, and a second coolant circuit configured to guide coolant in a heat exchange relationship with the at least one end turn portion. At least one flow controller is configured and disposed to selectively adapt coolant delivery through the first and second coolant circuits based on coolant temperature flowing from the stator. | 11-20-2014 |
20140339932 | ELECTRIC MACHINE INCLUDING A THERMAL CONTROL MODULE - An electric machine includes a stator. The stator includes a stator core, and a plurality of windings supported by the stator core. The plurality of windings include a first end turn portion and a second end turn portion. An adaptable cooling system is fluidically connected to the housing. The adaptable cooling system includes a first coolant circuit configured to guide a coolant in a heat exchange relationship with the stator core, and a second coolant circuit configured to guide a coolant in a heat exchange relationship with one of the first and second end turn portions. A thermal control module is operably connected to the adaptable cooling system. The thermal control module includes a coolant demand schedule described in a machine specific coolant map and is configured and disposed to selectively adapt coolant delivery to the first and second coolant circuits based on the coolant demand schedule | 11-20-2014 |
20140304978 | FLARING SYSTEM FOR FLARING STATOR WINDINGS - A flaring system for stator windings includes a base member, and a first cuff supported at the base member. The first cuff includes a first body having an inner annular surface that defines a first central opening. A second cuff includes a second body having an inner annular surface that defines a second central opening. A flaring guide includes an angled surface configured and disposed to rest upon the second body. A flare tool includes a flaring portion having an angled surface portion. The flaring portion is configured and disposed to extend between first and second stator winding layers of the a stator end turn portion with the angled surface portion urging one of the first and second stator winding layers radially outward against the angled surface of the flaring guide. | 10-16-2014 |
20140300234 | ROTARY ELECTRIC MACHINE ROTOR POLE CONFIGURATION - A rotor for a rotary electric machine, the rotor including first and second pole pieces each having a respective magnetic hub arranged for rotation about an axis along which they are spaced. Pluralities of magnetic first and second pole fingers are spaced from each other and extend between the hubs. Each pole finger has a proximal end connected to its respective hub, and an axially opposite distal end. The first and second pole fingers circumferentially alternate about the axis, and each pole finger has a respective radially inner surface defining a cavity that extends axially from the distal end to a cavity terminus. Relative to each pole finger, at a respective axial position between the distal end and the cavity terminus the radial distance between the axis and the radially inner surface is substantially greater inside of the cavity than outside of the cavity. | 10-09-2014 |
20140266043 | VEHICLE SYSTEM WITH BATTERIES IN SERIES - A vehicle system is provided and includes a 12 volt alternator and a 24 volt wound rotor configured for acceptance in the 12 volt alternator. | 09-18-2014 |
20140265714 | TRANSVERSE FLUX STATOR CORE MANUFACTURE - A transverse flux stator core is provided and includes laminations. Each of the laminations has a desired profile and is non-planar. The laminations are bonded in a stacked, aligned arrangement. | 09-18-2014 |
20140265710 | COIL ARRANGEMENT WITH INTERMEDIARY WIRE TIE-OFF - A coil arrangement for an electric machine comprises a spool including a hub, a first wall positioned on a first side of the hub, and a second wall positioned on a second side of the hub. A length of wire is wound on the hub to form a coil positioned between the first wall and the second wall of the spool. The coil includes a plurality of winding layers including an inner winding layer, an outer winding layer, and at least one intermediate winding layer between the inner winding layer and the outer winding layer. A projection is connected to the spool. The projection includes a first end directly connected to the spool and a second end opposite the first end, the second end is positioned between the first wall and the second wall of the spool. The outer winding layer engages the second end of the projection. | 09-18-2014 |
20140265702 | Electric Machine with Skewed Permanent Magnet Arrangement - A permanent magnet electric machine includes a stator and a rotor opposing the stator. Axial slots are provided in the rotor with a plurality of magnet stacks positioned in the slots. Each of the plurality of magnet stacks includes a plurality of magnet segments. The plurality of magnet segments includes a first number of first magnet segments and a second number of second magnet segments. The first magnet segments are offset from the second magnet segments in a circumferential direction of the rotor. The first number and the second number are both greater than one and the first number is different from the second number. | 09-18-2014 |
20140265683 | METHOD AND ARRANGEMENT FOR MOUNTING STATOR CORE IN HOUSING - An electric machine includes a plurality of windings, a stator core, and a housing. The stator core includes a substantially cylindrical outer surface with a plurality of protuberances extending from the outer surface. Each of the plurality of protuberances includes a flat side extending from the outer surface of the stator core in a radial direction and a rounded side opposite the flat side of the protuberance and extending from the outer surface of the stator core in the radial direction. The housing has a substantially cylindrical inner surface including a plurality of recesses configured to receive the plurality of protuberances on the outer surface of the stator core. Each of the plurality of recesses includes a flat side configured to engage the flat side of an associated protuberance and a round side having a contour matching the contour on the rounded side of the associated protuberance. | 09-18-2014 |
20140265680 | STARTER - Embodiments of the invention provide a starter that includes a motor with an armature that is coupled to a pinion. In some embodiments, the starter can include a main field coil that can be configured and arranged to produce a main magnetic field flux. Some embodiments of the invention provide a starter that includes an auxiliary field coil capable of being electrically coupled with the main field coil and can be configured and arranged to produce a supplemental magnetic field flux. In some embodiments, the auxiliary field coil is capable of being electrically coupled in series with the main field coil. In some other embodiments, the auxiliary field coil is capable of being electrically coupled in parallel with the main field coil. Some embodiments include a starter system. In some embodiments, a control system can operatively power the main field coil and the auxiliary field coil within the starter system. | 09-18-2014 |
20140265679 | STARTER - Embodiments of the invention provide a starter that includes a motor with an armature that is coupled to a pinion. In some embodiments, the starter can include a main field coil that can be configured and arranged to produce a main magnetic field flux. Some embodiments include at least one auxiliary flux assembly arranged in close proximity with the main field coil and electrically disconnected from it. In some embodiments, a control system can operatively power the main field coil to produce a magnetic field flux. In some embodiments, the at least one auxiliary flux assembly can provide a supplementary field flux adding to the main magnetic field flux that interacts with the armature. | 09-18-2014 |
20140265672 | PHASE LEAD INSULATOR - An alternator includes a phase lead insulator structured for electrically insulating and routing phase leads, the insulator including a channel guide having a width substantially equal to a width of one phase lead, the insulator including a retainer for retaining a phase lead within the channel guide. The phase lead insulator may include a circumferential channel guide having a width substantially equal to a width of a conductor and having a height substantially greater than or equal to a plurality of heights of such conductors and may include a retainer for retaining a conductor within the channel guide. A method of placing phase leads of an alternator includes bending at least one phase lead into the channel guide, and routing phase lead(s) to a corresponding connection position of a bridge rectifier. | 09-18-2014 |
20140265671 | HIGH EFFICIENCY B+ CONNECTION - An alternator includes a B+ bolt, rectifier B+ terminals, a bus having bends respectively surrounding ones of the rectifier B+ terminals and having an end formed into a ring terminal, and a stop, where the bus ring terminal is placed onto the B+ bolt and a load cable ring terminal may be placed onto the B+ bolt in direct contact with the bus ring terminal and secured thereto by the stop. A method of connecting B+ on an alternator includes bending a copper bus conductor so that one side of the bus conductor surrounds and abuts each of the rectifier B+ terminals, shaping one end of the bus conductor into a ring terminal, and placing the ring terminal of the bus conductor onto the B+ stud. A method includes coupling the B+ terminals and the B+ stud together with a copper bus conductor, and cooling the copper bus conductor. | 09-18-2014 |
20140265656 | ELECTRIC MACHINE INCLUDING A TEMPERATURE SENSING SYSTEM - An electric machine includes a housing, a stator including stator windings mounted to the housing, a rotor supported in the housing and configured to rotate relative to the stator, a temperature sensing system including one or more resistors mounted to one of the stator and the rotor, and a controller electrically connected to the one or more resistors. The controller is configured and disposed to determine a temperature of the one of the stator and the rotor based on an electrical parameter of the one or more resistors. | 09-18-2014 |
20140265331 | Alternator-Starter Assembly Having Gear Reduction System - An alternator-starter assembly for an internal combustion engine having a crankshaft and a drive member operatively connected to the crankshaft. The alternator-starter assembly includes an electric machine, a transmission assembly, and a controller. The electric machine includes a stator and a rotor that is configured for rotation relative to the stator. The transmission assembly includes a first drive shaft operatively connected to the rotor, a second drive shaft operatively connected to the drive member, and a gear assembly operatively connected to the first drive shaft and the second drive shaft. The controller is connected to the electric machine and is configured to operate the electric machine as a generator when the gear assembly is in a first gear configuration and to operate the electric machine as a motor when the gear assembly is in a second gear configuration. | 09-18-2014 |
20140260793 | STARTER MOTOR FOR A MOTOR VEHICLE - A starter motor includes a motor portion having a stationary field, an armature rotatable relative to the stationary field, an armature shaft coupled to the armature, and a pinion gear slideably disposed relative to the armature shaft and rotatably fixed relative to the armature. The starter motor also includes a solenoid mounted to the motor portion. The solenoid includes a plunger mechanically linked with the pinion gear. The solenoid is configured and disposed to cause the pinion gear to engage with a flywheel as the armature shaft reaches a speed between about 150 RPM and about 250 RPM. | 09-18-2014 |
20140260792 | STARTER - Some embodiments include a starter that includes at least one solenoid coil winding that is integrated with a pinion and plunger assembly. Some embodiments include a starter with an output shaft including a rotational axis coupled to a pinion including pinion teeth, and at least one solenoid coil winding at least partially circumferentially surrounding the pinion, the pinion teeth and the output shaft. In some embodiments, the solenoid coil winding is capable of providing a magnetic field flux within the pinion, the output shaft or both. Some embodiments provide a starter with a pinion that can move bi-directionally with respect to the rotational axis of the output shaft. In other embodiments, the output shaft includes splines and the pinion includes a slot with spline contours. In some further embodiments, a starter control system includes a starter that is capable of being in communication with an electronic control unit. | 09-18-2014 |
20140260740 | ELECTRIC MACHINE INCLUDING AN AXIAL RETAINER - An electric motor includes a gear assembly having at least one gear arranged within a stationary gear support. The stationary gear support includes an outer surface having an axial retainer mounting element. A drive shaft is operatively coupled to the at least one gear. An output shaft includes a first end and a second end. The second end is operatively coupled to the drive shaft. The output shaft is axially shiftable relative to the drive shaft in a first direction and in an opposing second direction. A clutch assembly is supported on the second end of the output shaft. The clutch assembly includes a clutch shell having a first end and a second end. An axial retainer is detachably mounted to the axial retainer mounting element. The axial retainer is configured and disposed to engage the second end of the clutch shell to limit axial travel of the clutch assembly. | 09-18-2014 |
20140246933 | LIQUID-COOLED ROTARY ELECTRIC MACHINE HAVING HEAT SOURCE-SURROUNDING FLUID PASSAGE - A liquid-cooled rotary electric machine including jacket defining a heat transfer surface in conductive thermal communication with a stator and having an axial end portion partially enclosing an interior volume. A heat source is in conductive thermal communication with a wall of the jacket axial end portion. A fluid channel traverses the heat transfer surface between opposite axial ends of the jacket. A fluid passage in fluid communication with the fluid channel is defined by jacket axial end portion walls and substantially surrounds the heat source in an imaginary plane perpendicular to the stator axis. At least a portion of heat transferable between the heat source and the fluid passage is convectively transferable between jacket axial end portion walls and liquid coolant along a flow path of liquid coolant through the machine. Also a method for liquid-cooling a rotary electric machine. | 09-04-2014 |
20140246931 | LIQUID-COOLED ROTARY ELECTRIC MACHINE HAVING FLUID CHANNEL WITH AUXILIARY COOLANT GROOVE - A liquid-cooled rotary electric machine including a heat transfer surface traversed by a fluid channel defining a flow path for liquid coolant through the machine. A first fluid channel portion extends about and progresses in a direction parallel to the central axis, and is interconnected with a second fluid channel portion at spaced locations along the first fluid channel portion. The heat transfer surface includes a zone which the first fluid channel portion does not traverse, and is located between a jacket axial end and the first fluid channel portion. The second fluid channel portion extends into the zone between the interconnections, whereby the zone is traversed by the second fluid channel portion and heat is convectively transferable from the zone to liquid coolant along the flow path. Also, a method for liquid-cooling a rotary electric machine. | 09-04-2014 |
20140246177 | LIQUID-COOLED ROTARY ELECTRIC MACHINE HAVING COOLING JACKET WITH BI-DIRECTIONAL FLOW - A liquid-cooled rotary electric machine including a jacket defining a heat transfer surface and a sleeve defining a coolant containment surface. A fluid channel having an entry and an exit is located between the heat transfer and coolant containment surfaces, and traverses the heat transfer surface. The fluid channel defines a flow path for liquid coolant through the machine extending substantially circumferentially about an axis and progressing in a direction parallel with the axis, with the flow path progressing in opposite directions parallel to the axis. Also, a method of liquid-cooling a rotary electric machine that includes traversing a generally cylindrical heat transfer surface with a liquid coolant flow along a flow path extending substantially circumferentially about an axis and progressing in opposite directions parallel to the axis, between a fluid channel entry and a fluid channel exit. | 09-04-2014 |
20140240067 | Solenoid with Variable Reluctance Plunger - A solenoid for a vehicle starter includes at least one coil with a passage extending through the coil in an axial direction. The solenoid further includes a plunger configured to move in the axial direction within the passage. The plunger includes a cylindrical outer surface with a substantially uniform diameter and a circumferential notch. The cylindrical outer surface includes a first portion with a first diameter on one side of the circumferential notch, and a second portion with the first diameter on an opposite side of the circumferential notch. The circumferential notch includes a portion with a second diameter that is less than the first diameter. | 08-28-2014 |
20140239767 | ELECTRIC MACHINE WITH V-RISER COMMUTATOR - A rotor for an electric machine includes a rotor core defining an axis of rotation, a plurality of windings positioned on the rotor core, and a commutator extending from the rotor core. The commutator includes an elongated contact portion and a riser connected to an end of the elongated contact portion. The riser includes a circumferential wall extending radially outward from the end of the elongated contact portion. The circumferential wall includes a V-shaped top portion with a plurality of notches formed in the V-shaped top portion. | 08-28-2014 |
20140217851 | ELECTRIC MACHINE AND A METHOD OF CONSTRUCTING A COMMUTATOR FOR AN ELECTRIC MACHINE - An electric machine and a method of forming a commutator for an electric machine includes forming a commutator assembly including a plurality of commutator bar members linked through a corresponding plurality of bridge elements, rolling the commutator assembly into a commutator form having a substantially continuous, uninterrupted, outer surface, introducing an internal support member that receives an end portion of each of the plurality of commutator bar members into an inner diameter of the commutator form, and separating the plurality of commutator bar members by removing each of the plurality of bridge elements creating a discontinuous outer surface. | 08-07-2014 |
20140197703 | ELECTRIC MOTOR ROTOR THERMAL INTERFACE FOR HUB/SHAFT - A cooling system of an electric machine includes a hub, a rotor core, and a thermal interfacial material interposed between respective complementary mating surfaces of the hub and the rotor core for substantially eliminating air gaps therebetween. A method of cooling an electric machine having a rotor core and a hub includes placing a thermal interfacial material onto a heat transfer interface between the rotor core and the hub, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method includes providing a rotor core having a radially inner surface, coating at least one of a radially outer surface of a hub and the radially inner surface of the rotor core with a thermal interfacial material, and inserting the hub into the rotor core, whereby the thermal interfacial material is interposed between the inner surface of the rotor core and the outer surface of the hub. | 07-17-2014 |
20140197702 | ELECTRIC MOTOR ROTOR THERMAL INTERFACE WITH AXIAL HEAT SINKS - A cooling system of an electric machine first and second heat sinks respectively mounted to axial ends of a rotor core, and a thermal interfacial material interposed between respective complementary surfaces of the heat sinks and the rotor core for substantially eliminating air gaps therebetween. A method of cooling includes placing thermal interfacial material onto a heat transfer interface between the rotor core and the heat sink, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method of cooling includes coating an axially outer surface of the rotor core and/or an axially inner surface of an annular heat sink with thermal interfacial material, and attaching the heat sink to the rotor, whereby thermal interfacial material is interposed between the inner surface of the heat sink and the outer surface of the rotor core. | 07-17-2014 |
20140197701 | ELECTRIC MOTOR STATOR HOUSING INTERFERENCE GAP REDUCING METHOD AND APPARATUS - A cooling system of an electric machine includes a stator core, a housing, and a thermal interfacial material interposed between complementary mating surfaces of the stator core and the housing for substantially eliminating air gaps therebetween. A method of cooling an electric machine having a housing and a stator includes placing a thermal interfacial material onto a heat transfer interface between the stator and the housing, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method of cooling a stator of an electric machine includes heating a housing having a radially inner surface, coating a radially outer surface of the stator and/or the radially inner surface of the housing with a thermal interfacial material, and inserting the stator into the heated housing, whereby the thermal interfacial material is interposed between the inner surface of the housing and the outer surface of the stator. | 07-17-2014 |
20140196282 | APPARATUS AND METHOD FOR INSTALLING STATOR WINDING CONDUCTORS - An apparatus for installing an elongate conductor into stator core slots, including a magazine having a radially outer cylindrical surface with recesses that extend inwardly of the cylindrical surface, and a circular rack having a radially outer periphery provided with rack slots. The magazine has an installation mode in which a stator core coaxially surrounds the magazine, there is concurrent radial alignment between pairs of magazine recesses and stator core slots, and a conductor axial branch is receivable by a stator slot from a respectively paired magazine recess; and a load mode in which the circular rack and the magazine have synchronized rotative movements, corresponding pairs of magazine recesses and rack slots are sequentially aligned, and a conductor axial branch is receivable by a magazine recess from its aligned rack slot. Also, a method for loading an elongate conductor onto a magazine for subsequent installation into stator core slots. | 07-17-2014 |
20140175917 | ROTOR ASSEMBLY HAVING A COOLANT AGITATION SYSTEM AND METHOD - A rotor assembly for an electric machine. The rotor assembly includes a shaft that defines a longitudinal axis of the electric machine, and a rotor body including a rotor hub supported by the shaft. The rotor body includes a first axial end and an opposing, second axial end. A coolant agitation system is provided on the rotor body. The coolant agitation system includes one or more coolant agitator members extending from one of the first and second axial ends. Each of the one or more coolant agitator members includes a first section that extends along the longitudinal axis and a second section that extends relative to the first section at a non-zero angle relative to the longitudinal axis. | 06-26-2014 |
20140175916 | ROTOR ASSEMBLY HAVING LIQUID COOLING - A liquid-cooled rotor assembly for a rotary electric machine, including a shaft provided with a fluid passageway receivable of a liquid coolant, and a substantially cylindrical rotor core rotatable in unison with the shaft. The rotor core is provided with a plurality of passages each terminating at a void in a rotor core axial end. Permanent magnets are disposed in rotor core passages, a gap is defined between each magnet and its respective rotor core passage. The shaft fluid passageway is in fluid communication with the rotor core end voids through the gaps, whereby the rotor core and the magnets are convectively cooled by liquid coolant receivable by the shaft fluid passageway and delivered to a rotor core end through the rotor core passages. Also, a method for liquid cooling a rotor assembly. | 06-26-2014 |
20140174818 | CONNECTOR MEMBER INCLUDING A LOCKING ELEMENT - A connector member includes a coupler portion having a wall including a first end that extends to a second end that defines a connection zone. The wall includes an outer surface. A mounting portion is provided at the first end. The mounting portion includes one or more cantilevered beam elements that extend along the wall spaced from the outer surface. A locking member extends about the coupler portion between the one or more cantilevered beam elements and the outer surface of the wall. The locking member is configured and disposed to limit deflection of the one or more cantilevered beam elements to prevent removal of the connector member from a substrate. | 06-26-2014 |
20140154086 | FRONT FAN RETENTION IN DUAL INTERNAL FAN ALTERNATOR - An alternator has a pole segment with a collar, an axially outward surface, and at least one key extending radially outward from the collar along the surface. A fan has a keying slot extending radially outward from a center ring, and a fan body including protrusions. The fan is mounted to the segment whereby the collar fits inside the ring and the key fits inside the keying slot, and the fan is welded to the segment at the protrusions. A method includes securing a fan to a pole segment by mating a radially-extending key formed on the segment to a keying slot of the fan and by welding the fan to the segment. | 06-05-2014 |
20140132094 | THERMAL MANAGEMENT OF AN IPM MOTOR WITH NON-MAGNETIC BARS - A rotor of an electric machine includes a lamination stack having a plurality of longitudinally extending magnet channels each having a magnet space and longitudinally extending gaps on each lateral end of the magnet space. A plurality of permanent magnets are respectively disposed in ones of the magnet channels, substantially non-magnetic bars are disposed in each longitudinally extending gap, and a thermally conductive filler material secures the magnets and the bars within the channels. A method of thermal management of an internal permanent magnet (IPM) rotor includes installing, into at least one longitudinally extending magnet channel of a lamination stack, a pair of substantially non-magnetic bars adjacent opposite lateral ends of a longitudinally extending permanent magnet, and transferring heat from the magnet through the bars into the lamination stack. | 05-15-2014 |
20140125258 | METHOD AND APPARATUS FOR REDUCING TORQUE VARIATION IN MOTOR DRIVE SYSTEMS - A method for controlling a specific electric machine includes receiving with a controller a back electromotive force (BEMF) coefficient for the specific electric machine. The controller is configured to control operation of an inverter coupled to the electric machine where the inverter is configured to provide or receive multi-phase electricity to or from the electric machine in motor mode or generator mode, respectively. The method further includes receiving with the controller an input related to a selected torque to be applied by or a selected power to be removed from the electric machine. The method further includes determining a first electrical parameter the inverter is to apply to in motor mode or a second electrical parameter the inverter is to convert power to in generator mode using the BEMF coefficient, and applying the first electrical parameter to the electric machine or converting the received power to the second electrical parameter. | 05-08-2014 |
20140117795 | MOTOR COOLING FEATURES - A cooling system of an electric machine includes a rotor having a shaft, a hub mounted to the shaft, and a core mounted to the hub. A bearing assembly is secured to the shaft and has a rotating portion and a fixed portion including a fluid inlet. A plurality of nozzle features are fluidly connected to the fluid inlet via a manifold. A cooling system of an electric machine includes a rotor having a shaft and a hub mounted to the shaft, a fluid inlet having a rotating portion and having a fixed portion, a fluid manifold, and a plurality of nozzle features disposed in the hub and fluidly connected to the fluid inlet via the manifold. A method of cooling an electric machine includes spraying coolant from a plurality of hub nozzles onto end turns of a stator winding. | 05-01-2014 |
20140111055 | CONDUCTOR WITH DIVOT FOR IMPROVED FORM FACTOR - A conductive element is provided and includes an electrically conductive material and a coating surrounding the electrically conductive material to form a coated member. The coated member is formed with a crown defined by bends in first and second transverse dimensions. The electrically conductive material is formed to define at least one divot proximate to the crown. The at least one divot is discernible through the coating. | 04-24-2014 |
20140111050 | IPM ROTOR MAGNET SLOT GEOMETRY FOR IMPROVED HEAT TRANSFER - A rotor includes a stack of metal laminations each having a plurality of magnet slots, corresponding magnet slots of the laminations being substantially aligned with one another and thereby forming longitudinal channels in the rotor, selected ones of the magnet slots having at least one feature protruding from at least one long side thereof. The rotor also includes a plurality of magnets each having a pair of long sides in cross-section, each magnet being disposed in a respective one of the longitudinal channels, and includes a thermal conductor connecting at least one of the long sides of one of the magnets with an adjacent long side of a magnet slot having the at least one feature. The feature abuts a long side of a respective one of the magnets at a distance away from the long side of the respective magnet slot. | 04-24-2014 |
20140096373 | METHOD FOR TWISTING AN ARMATURE - Methods and apparatus for fabricating an armature for a motor. In some embodiments, the conductors of an armature are bent according to a non-linear profile that results in better management of conductor stresses, and better final alignment of the position of the conductor free end. | 04-10-2014 |
20140093398 | ELECTRIC MACHINE INCLUDING A SHAFT HAVING A PUMP VANE - An electric machine includes an electric machine housing having a first end, a second end, and an interior. A stator is fixedly mounted relative to the electric machine housing. A pump housing is provided at one of the first and second ends. A rotor is rotatably supported relative to the stator. The rotor includes a shaft having a first end that extends to a second end through an uninterrupted intermediate portion having an outer surface. One of the first and second ends extends into the pump housing. At least one vane element projects from the outer surface and is arranged in the pump housing. | 04-03-2014 |
20140091649 | ELECTROMAGNETIC INTERFERENCE SHIELD AND BALANCE RING FOR ELECTRICAL MACHINE - An electrical machine including a stator and a rotor assembly. The rotor assembly defines a rotational axis and has a rotor core wherein the rotor core defines first and second axial end surfaces. A balance ring is rotationally fixed to the rotor assembly and is configured to rotationally balance the rotor assembly. The balance ring comprises an electrically conductive and magnetically permeable material and is disposed proximate the first axial end surface and defines an air gap disposed axially between the balance ring and the first axial end surface. In some embodiments, the electric machine includes a plurality of spacers extending between the first axial end surface and the balance ring. The rotor core and balance ring may comprise a plurality of stacked electrical steel laminations. The balance ring can be used to provide electromagnetic interference shielding for a resolver. A method of manufacturing an electric machine is also disclosed. | 04-03-2014 |
20140084740 | SLOT LINER FOR ELECTRO-DYNAMIC MACHINE - A slot liner is configured for association with a tooth of an electro-dynamic machine core having an annular rim and circumferentially spaced teeth radially extending from the annular rim. The slot liner includes sidewalls configured to line circumferential surfaces of the tooth, first and second tabs formed by bends in the sidewalls, the first tab being configured to line a portion of the annular rim adjacent to the tooth and the second tab being configured to overlap with a tab of an adjacent slot liner and a retainer configured to retain the sidewalls against a radially inward portion of the tooth. | 03-27-2014 |
20140070658 | LAMINATION ASSEMBLY INCLUDING AN INTER-LAMINATION THERMAL TRANSFER MEMBER FOR AN ELECTRIC MACHINE - A lamination assembly having a lamination stack including a plurality of lamination members, and at least one inter-lamination thermal transfer member coupled to at least one of the plurality of lamination members. The at least one inter-lamination thermal transfer member establishes a heat dissipation path from the lamination stack. | 03-13-2014 |
20140070654 | PERMANENT MAGNET ELECTRIC MACHINE HAVING MAGNETS PROVIDED WITH A THERMAL ENHANCEMENT BONDING COATING - A rotor assembly for a permanent magnet electric machine includes a plurality of rotor laminations joined to form a rotor body. Each of the plurality of rotor laminations includes a plurality of slots. One or more permanent magnets are mounted within respective ones of the plurality of slots. Each of the one or more permanent magnets includes a thermal enhancement bonding coating. A method of forming a rotor assembly is also disclosed. | 03-13-2014 |
20140070636 | ELECTRO-DYNAMIC MACHINE - An electro-dynamic machine is provided and includes stator assembly end turns and a coolant chargeable bladder disposable to contact the end turns. | 03-13-2014 |
20140070635 | PERMANENT MAGNET ELECTRIC MACHINE INCLUDING PERMANENT MAGNETS HAVING A SLEEVE FORMED FROM A THERMAL INTERFACE MATERIAL - An electric machine includes a housing, a stator fixedly mounted relative to the housing, and a rotor assembly rotatably mounted relative to the stator. The rotor assembly includes a plurality of rotor laminations forming a rotor body, one or more permanent magnets provided in the rotor body, and a sleeve extending around the one or more permanent magnets. The sleeve provides a thermal interface between the one or more permanent magnets and the rotor body. | 03-13-2014 |
20140054999 | METHOD OF MANUFACTURING AN ELECTRIC MACHINE WITH SEGMENTED PERMANENT MAGNETS - A method for manufacturing a magnet stack for placement in a core member of a permanent magnet electric machine includes providing a plurality of magnet segments, each of the plurality of magnet segments including opposing axial faces having a first surface finish. The method further includes assembling the plurality of first magnet segments into a magnet stack, the magnet stack including a first end with a first axial face of a first magnet segment and an opposing second end with a second axial face of a second magnet segment. Additionally, the method includes finishing the opposing ends of the magnet stack such that the first axial face and the second axial face have a second surface finish that different than the first surface finish. | 02-27-2014 |
20140042840 | PERMANENT MAGNET (PM) ELECTRIC MACHINE INCLUDING PERMANENT MAGNETS PROVIDED WITH A THERMAL INTERFACE MATERIAL (TIM) BETWEEN ADJACENT PERMANENT MAGNETS - A permanent magnet electric machine includes a housing, a stator mounted within the housing, and a rotor assembly rotatably mounted within the housing relative to the stator. The rotor assembly includes a rotor body having a plurality of rotor laminations. A plurality of permanent magnets having axial end portions is mounted to the rotor body. An amount of thermal interface material (TIM) is arranged between the axial end portions of adjacent ones of the plurality of permanent magnets. | 02-13-2014 |
20140041484 | STARTER PINION ENGAGEMENT TESTER - A method and apparatus for testing a starter assembly for an engine is provided. A test apparatus may include a controller operative to route power from a power supply to a tested starter assembly. The test apparatus may analyze a condition of the tested starter assembly based on monitored signals at one or more terminals of the starter assembly. A testing method may include monitoring an operating condition of the tested starter assembly during application of a variable voltage and/or current to an input of the starter assembly. | 02-13-2014 |
20140035426 | STATOR INCLUDING CONDUCTORS PROVIDED WITH A CERAMIC COVERING - A stator core includes a plurality of slot segments, a plurality of stator winding conductors arranged in select ones of the plurality of slot segments, and a ceramic covering provided on one or more of the plurality of stator winding conductors. The ceramic covering includes an adhesive bonded to the one of the plurality of stator winding conductors to provide insulation for the one or more stator winding conductors. | 02-06-2014 |
20140033514 | ELECTRIC MACHINE WITH SINGLE OR DUAL-SHAPE WINDING CONFIGURATION AND METHOD - A method of making a first stator winding and a second stator winding comprises forming an open winding arrangement on a first stator core, the open winding arrangement including conductor segments positioned in stator slots with at least four layers of conductor segments in each slot, the open winding arrangement further comprising a plurality of leads to a plurality of the conductor segments. The method further comprises forming the open winding arrangement on a second stator core. In addition, the method comprises closing the open winding arrangement on the first stator core by connecting the plurality of leads with first additional conductors to form a three phase winding in a single-shape configuration. Furthermore, the method comprises closing the open winding arrangement on the second stator core by connecting the plurality of leads with second additional conductors to form a three phase winding in a multi-shape configuration. | 02-06-2014 |
20130342030 | HIGH VOLTAGE PROTECTION INTERLOCK SYSTEM FOR SERVICEABILITY - An interlock system and method are provided for protecting high voltage electrical couplings. The interlock system may control access to the electrical couplings based on the voltage of the electrical couplings. The interlock system may also selectively energize and de-energize the electrical couplings based on the position of a lid. | 12-26-2013 |
20130334911 | ELECTRIC MOTOR INCLUDING A POSITIVE PRESSURE INTRODUCTION SYSTEM AND METHOD - An electric machine includes a housing having an interior portion, a stationary member including a stationary field is fixedly mounted to the housing and a movable member including a rotating field is rotatably mounted relative to the stationary member. A positive pressure introduction system is fluidically coupled to the housing. The positive pressure introduction system is configured and disposed to raise an internal pressure of the interior portion of the housing. | 12-19-2013 |
20130334776 | MACHINE HOUSING HAVING A CONDUCTOR SEAL SYSTEM - A machine housing includes a conductor seal system including an outer seal member and an inner seal member. The outer seal member has an outer seal body formed from a first material. The outer seal body includes an outer surface portion and an inner surface portion defining a central opening. The outer surface portion includes a housing gripping portion and the inner surface portion includes at least one retention feature arranged within the central opening. The inner seal member includes an inner seal body formed from a second material. The inner seal body includes an outer surface having at least one retaining element configured and disposed to engage with the at least one retention feature to join the inner seal member to the outer seal member to establish a water proof and dust proof seal at the opening extending through the housing body. | 12-19-2013 |
20130327182 | ARMATURE WITH TORQUE LIMITER FOR ENGINE STARTER - An engine starter includes a gear assembly including a pinion gear. The engine starter further comprises an electric motor including an armature coupled to the gear assembly and configured to drive the gear assembly and the pinion gear. The armature includes a core member defining a central cavity extending in an axial direction within the core member. An armature shaft extends from the central cavity. A clutch arrangement is positioned in the central cavity. The clutch arrangement is configured to releasably couple the core member and the armature shaft. | 12-12-2013 |
20130320789 | CONCENTRIC MOTOR POWER GENERATION AND DRIVE SYSTEM - An apparatus is provided and includes a hub, including opposing faces, a first sidewall fixed to the opposing faces to define a first interior and a second sidewall fixed to one of the opposing faces to define a second interior within the first interior, a first assembly, disposed within the second interior, to generate current from input mechanical energy, a second assembly, electrically coupled to the first assembly and disposed within the first interior, to generate mechanical energy to be transmitted to external mechanical elements from current associated with the current generated by the first assembly and first and second couplings, the first coupling being disposed to mechanically couple the first and second assemblies and the second coupling being disposed to mechanically couple the second assembly and the external mechanical elements. | 12-05-2013 |
20130313923 | THERMALLY CONDUCTIVE COATING FOR PERMANENT MAGNETS IN ELECTRIC MACHINE - A method of manufacturing an electric machine that includes providing a core defining a slot, coating a magnet body prior to installation of the magnet body into the slot and installing the magnet body into the slot wherein the coating on the magnet body has a thermal conductivity of at least about 0.3 W·m | 11-28-2013 |
20130300131 | METHOD OF OPERATING VARIABLE FLUX ELECTRIC STARTER MACHINE HAVING DUAL FIELDS - A method of operating a variable flux electric machine includes passing an electrical current through a plurality of wound poles of a wound field to generate a first flux, rotating an armature at a first crank point having a first speed in response to the first flux, shorting at least one of the plurality of wound poles, generating a second flux through a permanent magnet (PM) field having a plurality of PM poles, and rotating the armature at a second crank point having a second speed in response to the second flux, the second speed being greater than the first speed. | 11-14-2013 |
20130300130 | VARIABLE FLUX ELECTRIC STARTER MOTOR AND METHOD OF OPERATING THE SAME - A variable flux electric starter motor includes a frame, an armature rotatably mounted within the frame, and a primary field mounted to the frame. The primary field includes a plurality of primary windings electrically connected one to another. A relay is electrically coupled to at least one of the plurality of poles. A supplemental field is mounted to the frame. The supplemental field includes a supplemental winding electrically connected in parallel to the plurality of primary windings. | 11-14-2013 |
20130300129 | VARIABLE FLUX ELECTRIC STARTER MACHINE HAVING DUAL FIELDS AND METHOD OF OPERATING THE SAME - A variable flux electric machine including a frame, an armature rotatably mounted within the frame, a first field having a plurality of windings that defines at least one wound pole fixedly mounted relative to the frame, a second field having at least one permanent magnet (PM) that defines at least one PM pole fixedly mounted relative to the frame, and a relay electrically coupled to the plurality of windings of the first field. | 11-14-2013 |
20130293194 | ALTERNATOR WITH LOCKOUT MODE - A lockout circuit which limits the field voltage in an alternator while the vehicle starter is activated. The lockout circuit may be configured to limit the field voltage while the charging circuit voltage is below a threshold value. A timer circuit may advantageously be employed with the lockout circuit. A temperature compensating function may also be employed to change the threshold value in response to temperature changes. The disclosed circuit is particularly advantageous when employed in cold weather conditions. A method of starting the engine of a vehicle is also disclosed. | 11-07-2013 |
20130244502 | TERMINAL BLOCK INCLUDING A CONDUCTOR ROUTING SYSTEM FOR AN APPARATUS INCLUDING AN ELECTRICAL COMPONENT AND METHOD OF ROUTING A CONDUCTOR ACROSS A TERMINAL BLOCK - A terminal block for an apparatus includes at least one terminal conductor having a first end that extends to a second end. The first end includes a first connection portion and the second end includes a second connection portion. A non-electrically conductive member covers the at least one terminal conductor. The non-electrically conductive member includes a body having a first end section arranged at the first end extending through an intermediate section to a second end section arranged at the second end. The first end section includes a first opening exposing the first connection portion, and the second end portion includes a second opening exposing the second connection portion. The body further includes a conductor routing system having at least one conductor routing member configured and disposed to restrain and guide a conductor member across the at least one terminal conductor. | 09-19-2013 |
20130237361 | REVERSIBLE PLANETARY GEAR ASSEMBLY - A planetary gear assembly includes a ring gear configured for connection to a rotor of an electric motor when in a first position and configured for connection to a housing of the electric motor when in a second position, a sun gear configured for connection to the housing when the ring gear is in the first position and configured for connection to the rotor when the ring gear is in the second position, and a plurality of planet gears configured to mesh with the ring gear and the sun gear. | 09-12-2013 |
20130221798 | ALTERNATOR RATIOS - A vehicle alternator has a center rotational axis and includes a substantially round stator having a plurality of coils, each coil being wound a number of times N around the stator. The vehicle alternator includes a rotor having a spool with a field coil wound thereon and having an opposed pair of core segments defining a number of interleaved pole portions P, each segment having a hub radially extending a distance R | 08-29-2013 |
20130214624 | ELECTRIC MACHINE COOLING - Embodiments of the invention provide an electric machine module including an electric machine. The electric machine includes a rotor and a stator assembly, and an output shaft having a longitudinal axis that is circumscribed by a portion of the rotor. The output shaft may comprise an output shaft channel and the rotor may include a rotor channel, and the rotor and the output shaft channels may be in fluid communication. The machine further includes a coolant jacket at least partially within a sleeve member that circumscribes at least a portion of the stator assembly, and at least one pump mounted generally concentrically with respect to the output shaft, that is in fluid communication with the coolant jacket. Some embodiments of the electric machine module include coupling to a fluid system that is configured and arranged to transport fluid, such as the coolant, throughout the fluid system. | 08-22-2013 |
20130203540 | CENTER ADAPTER ASSEMBLY - An adapter assembly is provided and includes a body having a first periphery, a second periphery opposite the first periphery and a central region interposed between the first and second peripheries. The first periphery is attachable to a first housing at a first aperture thereof, the first housing defining an interior in which a first motor is disposable. The second periphery is attachable to a second housing at a second aperture thereof, the second housing defining an interior in which a second motor is disposable. The central region is configured to encase a coupling for operably coupling the first and second motors via the first and second apertures, respectively, for output to a shaft. | 08-08-2013 |
20130199509 | Solenoid with Variable Reluctance Plunger - A solenoid for a vehicle starter includes at least one coil with a passage extending through the coil in an axial direction. The solenoid further includes a plunger configured to move in the axial direction within the passage. The plunger includes a cylindrical outer surface with a substantially uniform diameter and a circumferential notch. The cylindrical outer surface includes a first portion with a first diameter on one side of the circumferential notch, and a second portion with the first diameter on an opposite side of the circumferential notch. The circumferential notch includes a portion with a second diameter that is less than the first diameter. | 08-08-2013 |
20130187518 | SOLENOID COIL WITH REVERSE TURN - A solenoid arrangement includes a plunger configured to move in an axial direction and a coil wound radially outward from the plunger. The coil includes a first winding layer and at least one additional winding layer positioned radially outward from the first winding layer. The first winding layer includes a first portion wound in a first winding direction and a second portion wound in a second winding direction that is opposite the first winding direction. The at least one additional winding layer is wound in the second winding direction radially outward from both the first portion and the second portion of the first winding layer.. | 07-25-2013 |
20130187494 | STATOR ASSEMBLY FOR AN ELECTRIC MACHINE - A stator assembly includes a first conductor having a first leg portion, and second leg portion. Each of the first and second leg portions includes corresponding first and second free end portions. The first free end portion includes first and second surface portions and the second free end portion includes first and second surface segments. A second conductor includes a first leg section, and a second leg section including corresponding first and second free end sections. The first free end section includes first and second surface zones and the second free end section including first and second surface sectors. The second free end portion and the first free end section are twisted creating a cross-over region causing the first surface portion to abut the second surface zone. The second free end portion is joined to the first free end section through a bond that exists at the cross-over region. | 07-25-2013 |
20130173144 | Starter Motor Assembly - A control system for the starter assembly of an engine includes a first field effect transistor (FET) electrically connected between an electrical power supply and the starter motor and a second FET electrically connected between the power supply and the solenoid. A control unit is electrically connected to the gate of each FET and is configured to selectively apply a voltage to each gate, wherein the FET provides a current to the respective starter motor and solenoid as a function of the applied voltage. The control unit can selectively apply the gate voltages for cold start, soft start, and start-stop operation of the engine, and in response to sensor signals received by the control unit, such as ring gear rotational speed. | 07-04-2013 |
20130169103 | CONDUCTOR WELD-END FORMING PROCESS - A method of joining a plurality of electrical conductors in an electric machine comprises the steps of providing a core with a plurality of circumferentially spaced openings, and positioning a plurality of conductors within the openings of the core in a plurality of concentric layers. Each conductor includes an end that extends from the core. The ends of the conductors have a first shape. The method also includes the step of shaping the ends of the conductors with a set of forming dies to form a second shape. Additionally, the method includes the step of joining a pair of adjacent ends with a joining tool to form a joint with a third shape after shaping the ends to form the second shape. The method further includes the step of removing the set of forming dies and the joining tool from the joint after the joining step. | 07-04-2013 |
20130169098 | MULTI-GRADE MAGNET FOR AN ELECTRIC MACHINE - Apparatus and methods for improved performance of electric machines, including internal permanent magnet electric machines. In some embodiments there are multiple pairs of permanent magnets. Each magnet is fabricated from a pair of materials, one of the materials being selected to have improved high temperature magnetic characteristics, and the second material, in some embodiments, being selected for having improved magnet characteristics at lower temperatures even if with lesser magnetic characteristics at the higher temperatures than the other material. | 07-04-2013 |
20130169084 | STARTER MOTOR INCLUDING A CONDUCTOR MOUNTING ELEMENT - A starter motor including a frame having a terminal mounting portion, and a field fixedly mounted relative to the frame. An armature is rotatably supported relative to the field. A conductor having a terminal mounting section is electrically connected to one of the field and the armature. A terminal extends through the terminal section of the conductor and the terminal mounting portion of the frame. The terminal includes a plurality of threads. A conductor mounting element threadably engages with the plurality of threads. The conductor mounting element is configured to form a threaded clamped connection that establishes a solid metal compressive stack up connection between the conductor and the terminal | 07-04-2013 |
20130169083 | Overmolded Interlock Assembly For Electric Machine - An electric machine is provided including a housing, a stator assembly positioned within the housing, and a machine lead electrically coupled to the stator assembly. A terminal block assembly is overmolded onto an external lead to provide a covered environment for electrically coupling the external lead to the machine lead. | 07-04-2013 |
20130168974 | Starter Motor Assembly With Soft Start Solenoid - A solenoid in an engine starter assembly includes an electromagnetic coil operable on a plunger coupled to a shift lever to move a pinion gear into contact with the engine ring gear. The solenoid is provided with a return spring to restore the plunger to an initial position in which the pinion and ring gears are disengaged, in the absence of a coil force. A contact plate is supported on the plunger to engage open electrical contacts when the plunger is in a first position to complete an electrical circuit to drive the starter motor rotating the pinion gear at a faster speed. An over-travel spring resists movement of the plunger once the contact plate engages the electrical contacts. An auxiliary spring is disposed on the plunger to resist movement of the plunger only when the plunger travels to a position offset between the initial position and the first position. | 07-04-2013 |
20130167790 | Dual Synchronized Starter Motors - A starter motor arrangement comprises a battery, a first starter motor including a first pinion and a second starter motor including a second pinion. The first starter motor is connected in series to the battery and the second starter motor is connected in series to the first starter motor. Accordingly, the battery, the first starter motor, and the second starter motor are all connected in series. The first pinion gear and the second pinion gear are configured to engage an engine ring gear when electrical current flows through the first starter motor and the second starter motor. | 07-04-2013 |
20130156071 | Electric Machine Including Insulated Slot Liner With Temperature Sensor - A slot liner is configured for insertion into a slot of a core of an electric machine having a winding arrangement comprised of a plurality of conductors. The slot liner comprises a first insulation layer forming a cavity configured to receive at least one of the plurality of conductors of the winding arrangement. The slot liner also comprises a second insulation layer coupled to the first insulation layer. In addition, the slot liner includes a length of conductive material positioned between the first insulation layer and the second insulation layer. The length of conductive material has a resistance that varies with temperature. A first lead extends from a first end of the length of conductive material and a second lead extends from the second end of the length of conductive material. | 06-20-2013 |
20130147306 | Spacer For Supporting Conductors In An Electric Machine - A spacer for supporting conductors in a stator assembly of an electric machine includes a plurality of positioning elements cooperating with various conductors in the specials region of the winding arrangement. The spacer illustratively includes an insulating body formed of an electrically non-conductive material and including surfaces facing axially inwardly for contacting short conductors and crossover pockets for receiving crossover conductors which electrically connect an inner winding set and an outer winding set. The spacer further illustratively includes phase lead pockets facing axially outwardly for receiving a terminal phase lead conductor. | 06-13-2013 |
20130147289 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Some embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, a coolant jacket can be at least partially positioned within the housing. Some embodiments include a sleeve member at least partially surrounding the coolant jacket. In some embodiments, a stator assembly including stator end turns can be at least partially disposed within the housing and can be at least partially circumferentially surrounded by the coolant jacket. Some embodiments provide at least one coolant apertures being in fluid communication with the coolant jacket. Some embodiments can include at least one end turn cavity at least partially surrounding a stator end turn and fluidly coupled to the coolant jacket via at least one coolant aperture. In some embodiments, the at least one end turn cavity is in fluid communication with the coolant jacket and the machine cavity. | 06-13-2013 |
20130141192 | STARTER SYSTEM - Some embodiments of the invention provide a starter system including a starter, capable of being in communication with an electronic control unit. The starter can include a motor coupled to a circuit and a pinion including a plunger, and a plurality of solenoid assemblies including a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger, and at least one solenoid assembly capable of holding the plunger, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit that is capable of being activated by the plunger to control current flowing to at least a portion of the circuit. Some embodiments include at least two power isolation switches capable of controlling a current flow within the circuit. | 06-06-2013 |
20130140925 | STATOR INCLUDING CONDUCTORS PROVIDED WITH A COMPOSITE SLEEVE - A stator includes a stator core having a plurality of slot segments, a plurality of stator winding conductors arranged in select ones of the plurality of slot segments, a jumper conductor interconnecting select ones of the plurality of stator winding conductors to form one or more stator windings, a common conductor connected to at least one of the stator winding conductors, a phase conductor connected to corresponding ones of the one or more stator windings, and a composite sleeve provided on at least one of the jumper conductor, the common conductor, and the phase conductor. The composite sleeve includes a first sleeve, and a second sleeve positioned about the first sleeve. One of the first and second sleeves is formed from a compressed amide synthetic fiber. The first and second sleeves cooperate to provide protection for the conductor from external elements. | 06-06-2013 |
20130140081 | COMPOSITE SLEEVE FOR A CONDUCTOR AND METHOD - A composite sleeve for a conductor including a conductor having an outer surface, a first sleeve positioned about the outer surface of the conductor, and a second sleeve positioned about the first sleeve. One of the first and second sleeves is formed from a compressed amide synthetic fiber. The first and second sleeves cooperate to provide protection for the conductor from external elements. | 06-06-2013 |
20130139645 | Starter Motor with Torque Limiter - A starter motor includes a housing, a planetary gear assembly, and a plurality of detents. The housing defines an interior space. The planetary gear assembly is at least partially positioned in the interior space and includes a plurality of planetary gear components. The planetary gear components include a sun gear, an annulus, a plurality of planet gears, and a planetary gear carrier. The plurality of detents is configured to releasably retain a rotational position of a component of the planetary gear components relative to the housing. Each of the detents includes a biasing member and a bearing member. | 06-06-2013 |
20130135065 | STARTER SYSTEM - Some embodiments of the invention provide a starter system including a starter, capable of being in communication with an electronic control unit. The starter can include a motor coupled to a circuit and a pinion including a plunger, and a plurality of solenoid assemblies including a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger, and at least one solenoid assembly capable of holding the plunger, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit that is capable of being activated by the plunger to control current flowing to at least a portion of the circuit. Some embodiments include at least two power isolation switches capable of controlling a current flow within the circuit. | 05-30-2013 |
20130133605 | STARTER SYSTEM - Some embodiments of the invention provide a starter system including a starter, capable of being in communication with an electronic control unit. The starter can include a motor coupled to a circuit and a pinion including a plunger, and a plurality of solenoid assemblies including a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger, and at least one solenoid assembly capable of holding the plunger, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit that is capable of being activated by the plunger to control current flowing to at least a portion of the circuit. Some embodiments include at least two power isolation switches capable of controlling a current flow within the circuit. | 05-30-2013 |
20130133604 | STARTER SYSTEM - Some embodiments of the invention provide a starter system including a starter, capable of being in communication with an electronic control unit. The starter can include a motor coupled to a circuit and a pinion including a plunger, and a plurality of solenoid assemblies that includes a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger to move the pinion, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit. In some embodiments, the first switch is capable of being activated by the plunger to cause current to flow, or to prevent current flowing to at least a portion of the circuit. | 05-30-2013 |
20130127288 | ELECTRIC MACHINE WITH INSULATOR SPACER - A stator assembly for an electric machine including a stator core supporting a plurality of electrical conductors. A plurality of elongated insulator spacers is interwoven between the conductors proximate connection ends thereof in axially spaced relation to the stator core. | 05-23-2013 |
20130127287 | METHOD OF P-FORMING A CONTINUOUS CONDUCTOR HAVING A RECTANGULAR CROSS SECTION AND A STATOR INCLUDING A STATOR WINDING FORMED FROM A P-FORMED CONDUCTOR HAVING A RECTANGULAR CROSS-SECTION - A method of P-forming a conductor having a rectangular cross-section to create a continuous stator winding. The method includes forming a conductor having a rectangular cross-section into a series of first and second substantially parallel segments that meet at a vertex, deforming the conductor such that each of the first and second segments are non-parallel to form a cross-over feature at the vertex, and deforming a section of each of the first and second segments to include corresponding first and second portions that are generally parallel to create the continuous stator winding. | 05-23-2013 |
20130127286 | CONTINUOUS STATOR WINDING HAVING A RECTANGULAR CROSS-SECTION AND METHOD - A continuous stator winding includes a conductor having a rectangular cross-section, and a plurality of loops formed in the conductor. Each of the plurality of loops includes first and second substantially straight segments joined by at least one angled segment. A cross-over feature is formed in the at least one angled section. The cross-over feature includes a deformation formed in the conductor configured and disposed to nest with other conductors that form the stator winding. | 05-23-2013 |
20130127270 | METHOD OF WINDING A STATOR CORE WITH A CONTINUOUS CONDUCTOR HAVING A RECTANGULAR CROSS-SECTION AND A STATOR CORE - A method of inserting a continuous conductor having a rectangular cross-section into slot segments formed in a stator core includes deforming in a first direction a core member having a first end portion that extends to a second end portion to widen an opening at end portions of the slot segments, inserting one or more continuous conductors having a rectangular cross-section into select ones of the slot segments, and deforming in a second direction the core member to narrow the opening at end portions of the slot segments. | 05-23-2013 |
20130127269 | METHOD OF OPERATING AN ELECTRIC MACHINE HAVING AN INTEGRATED COOLANT LEVEL SENSOR - A method of operating an electric machine includes flowing a coolant into an interior portion of a housing of the electric machine, and sensing a level of coolant in a coolant collection area within the interior portion with a coolant level sensor arranged at the housing. | 05-23-2013 |
20130125396 | WRAPPED WIRE FOR ELECTRIC MACHINE - A method of insulating a conductor wire comprises the steps of providing an electrically conductive core having a longitudinal axis and applying an electrical insulation material to an outer surface of the core. The method further comprises the steps of elevating the temperature of the electrical insulation material and applying external pressure to the electrical insulation material to facilitate adhesion with the core. | 05-23-2013 |
20130113312 | Method and Apparatus for Fastening Cooling Fans to Electro-Mechanical Machines - A rotor arrangement for an electric machine comprises a rotor shaft and a rotor segment coupled to the rotor shaft. The rotor segment includes a main body and a collar integral with the main body. The collar includes an outer peripheral groove adjacent to the main body portion of the rotor segment. The rotor arrangement further includes a cooling fan that has a center opening defined by an inner perimeter. The center opening of the fan is configured to slidably engage the collar and is adjustable between an insertion diameter and a locking diameter. When the center opening is at the locking diameter, at least a portion of the inner perimeter of the fan extends into the outer peripheral groove in the collar such that the fan is retained on the rotor segment. | 05-09-2013 |
20130106231 | CONDUCTOR WELD-END LENGTH CONTROL FORMING | 05-02-2013 |
20130076176 | STATOR TERMINAL BLOCK FOR A MULTI-PHASE ELECTRIC MACHINE - A stator terminal block including a body member, a plurality of terminal elements provided on the body member, a plurality of stator winding receiving elements provided on the body member and one or more connector members are provided at the body member. The one or more connector members electrically interconnect select ones of the plurality of stator winding receiving elements. A plurality of connector elements is provided at the body member. The plurality of connector elements electrically interconnect select ones of the one or more connector members with select ones of the plurality of terminal elements. | 03-28-2013 |
20130076173 | ALTERNATOR HAVING A HEAT SINK AND METHOD - An alternator includes a housing having an inner surface and an outer surface, a stationary field coil component fixedly mounted to the inner surface of the housing through one or more mechanical fasteners, and a heat sink component mounted to the outer surface of the housing. The heat sink component includes one or more openings that align with corresponding ones of the one or more mechanical fasteners. | 03-28-2013 |
20130076167 | Cooling system and method for electronic machines - Embodiments of the invention provide an electric machine module including a housing. The housing can include a first and a second end cap. The first end cap can comprise a first and a second manifold and an inlet and outlet. The inlet and outlet can be in fluid communication with the first manifold and the second manifold, respectively. The second end cap can include a third manifold. The module can include an electric machine operatively coupled to the housing. The electric machine can include a stator assembly. The stator assembly can comprise at least one first and at last one second coolant member disposed within the stator assembly. The electric machine can be coupled to the housing so that the first coolant member can be in fluid communication with the first and third manifolds and the second coolant member can be in fluid communication with the second and third manifolds. | 03-28-2013 |
20130074652 | Starter Motor Having Clutch with Grooved Roller Elements - A clutch includes an outer clutch member, an inner clutch member, and a plurality of roller members. The outer clutch member defines an opening, and the inner clutch member is at least partially positioned within the opening. The inner clutch member includes a clutch surface. The plurality of roller members is at least partially positioned within the opening between the clutch surface and the outer clutch member. The roller members define a plurality of roller surfaces separated by at least one annular groove. Each of the roller members is displaceable within the opening to position the roller surfaces into engagement with the clutch surface to lock the inner clutch member into synchronous movement with the outer clutch member in response to movement of the inner clutch member in a rotational direction. | 03-28-2013 |
20130069474 | COMPOSITE CONDUCTOR INSULATION - An electric machine having insulated conductor wires and a method of insulating the conductor wires. The conductor wires include an electrically conductive core and an electrical insulation portion. The electrical insulation portion includes an electrical insulation coating layer and at least one electrical insulation wrap layer. | 03-21-2013 |
20130061457 | METHOD OF FORMING A ROTOR LAMINATION ASSEMBLY - A method of forming a rotor lamination assembly for an electric machine includes aligning a plurality of laminations to form a rotor lamination assembly. The rotor lamination assembly includes an outer diametric surface. The method also includes mounting a rotor lamination compression sleeve to the outer diametric surface of the rotor lamination assembly. The rotor lamination compression sleeve radially compresses the plurality of laminations. | 03-14-2013 |
20130033145 | ELECTRIC MACHINE MODULE INSULATION SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module including a housing which can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots. In some embodiments, conductors can be positioned in the slots and can include a first insulation. At least one insulation member can be disposed over at least a portion of the conductors. The insulation member can include a first element and a second element that can each comprise different constituent materials that include different properties. | 02-07-2013 |
20130015740 | Rotor Assembly for an Electric MachineAANM Chamberlin; Bradley D.AACI PendletonAAST INAACO USAAGP Chamberlin; Bradley D. Pendleton IN USAANM Ramey; James J.AACI FortvilleAAST INAACO USAAGP Ramey; James J. Fortville IN US - Some embodiments of the invention include a rotor assembly for an electric machine, including a rotor hub module. In some embodiments, the rotor hub module can include a body comprising a first and second group of apertures, an output shaft through a generally radially central portion of the body, and a support region along a generally radially outward portion of the body. In some embodiments a plurality of ribs can radially extend from a region of the body adjacent to the output shaft aperture to a region of the body adjacent to the support region. In some embodiments a plurality of rotor laminations can be operatively coupled to a portion of an outer diameter of the support region. | 01-17-2013 |
20130015735 | Cooling System and Method for Electronic MachinesAANM Lepres; AttilaAACI MezokovesdAACO HUAAGP Lepres; Attila Mezokovesd HUAANM Komlossy; KarolyAACI DebrecenAACO HUAAGP Komlossy; Karoly Debrecen HUAANM Andejcsik; GaborAACI VeresegyhazAACO HUAAGP Andejcsik; Gabor Veresegyhaz HU - Some embodiments of the invention provide an electric machine module include a housing. In some embodiments, the housing can include at least one end cap coupled to a central member. The housing can include a first axial end and a second axial end. The central member can include at least a portion of a coolant pipe, which can include end portions extending at least partially through the end cap. In some embodiments, an electric machine, which can include a stator assembly, can be positioned within the housing so that the coolant pipe is substantially coiled around at least a portion of an outer perimeter of the stator assembly. | 01-17-2013 |
20130015728 | Electric Machine Module Cooling System and MethodAANM Chamberlin; Bradley D.AACI PendletonAAST INAACO USAAGP Chamberlin; Bradley D. Pendleton IN USAANM Ramey; James J.AACI FortvilleAAST INAACO USAAGP Ramey; James J. Fortville IN USAANM Creviston; Alex S.AACI MuncieAAST INAACO USAAGP Creviston; Alex S. Muncie IN US - Embodiments of the invention provide an electric machine module comprising a module housing. In some embodiments, the module housing can include a sleeve member and at least one end cap. Also, an inner wall of the module housing can at least partially define a machine cavity. In some embodiments a coolant jacket can be positioned within a portion of the sleeve member. Further, in some embodiments, at least one partition can be positioned substantially within the coolant jacket. The partition can be dimensioned to at least partially seal a first region of the coolant jacket from a second region of the cooling jacket. | 01-17-2013 |
20120305226 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module. The module can include a housing that can define a machine cavity. The housing can include a coolant jacket that contains a first coolant. A coolant sump can be in fluid communication with the machine cavity and can contain a second coolant that is different than the first coolant. The coolant sump can be in thermal communication with the coolant jacket. An electric machine can be positioned within the machine cavity. The electric machine can include a stator assembly, a rotor assembly, and a shaft. The module can also include at least one coolant channel, at least one shaft channel, and at least one rotor channel. | 12-06-2012 |
20120286596 | Cooling Combinations for Electric Machines - Some embodiments of the invention provide an electric machine module comprising a housing including a sleeve member and at least one end cap. In some embodiments, the sleeve member can include a first coolant jacket and a second coolant jacket. Also, in some embodiments, the end cap can include an end cap coolant jacket. Also, some embodiments provide an electric machine including stator end turns, housing at least partially enclosing the electric machine, and an end cap coolant jacket positioned substantially axially outward relative to at least one of the stator end turns. | 11-15-2012 |
20120280585 | TANDEM ELECTRIC MOTOR VEHICLE DRIVE SYSTEM - A vehicle drive system includes a first electric motor having a first motor housing and a first motor shaft, a second electric motor having a second motor housing and a second motor shaft, and a gear system operatively connecting the first motor shaft and the second motor shaft. The gear system is configured and disposed to transmit torque from the first motor shaft to the second motor shaft to form a tandem electric motor drive system. | 11-08-2012 |
20120280582 | Method and Arrangement for Cooling Claw-Pole Electric Machines - An electric machine includes a stator and a rotor configured to rotate about an axis of rotation in a direction of angular rotation. The rotor includes a first claw-pole segment and an opposing second claw-pole segment. The first claw-pole segment includes a plurality of fingers extending from an end ring. Each finger includes a distal end and a proximal end with the proximal end fixed to the end ring. Each finger also includes an interior side and an exterior side with the exterior side facing the stator. A leading side and a trailing side are defined on each finger by the direction of angular rotation. A chamfer is formed on the exterior trailing side of each finger at the proximal end of the finger. | 11-08-2012 |
20120262013 | Electric Machine Module Cooling System and Method - Embodiments of the invention provide an electric machine module. The module can include a module housing, which can comprise a sleeve member. In some embodiments, the sleeve member can include an inner wall and an outer wall, and the module housing can at least partially define a machine cavity. In some embodiments, a coolant jacket can be positioned substantially between a portion of the inner wall and a portion of the outer wall. Also, in some embodiments, at least one boss can be positioned in the sleeve member so that the at least one boss can be substantially integral with both the inner wall and the outer wall, and can extend through a portion of the coolant jacket. | 10-18-2012 |
20120258833 | ASYNCHRONOUS BOOST ASSIST SYSTEM FOR A MOTOR VEHICLE - An asynchronous boost assist system for a motor vehicle includes a first electric motor, a second electric motor positioned opposite the first electric motor and a differential gear system operatively connected to the first and second electric motors. The differential gear system includes a first differential gear set and a second differential gear set. The first differential gear set is operatively connected to the first and second electric motors and the second differential gear set is configured and disposed to operatively connect to first and second vehicle wheels. A controller is operatively connected to each of the first and second electric motors. The controller selectively independently controls an operational speed of each of the first and second electric motors to selectively provide an acceleration boost through the second differential gear set. | 10-11-2012 |
20120238142 | Electric Machine with Fully Enclosed In-Slot Conductors - An electric machine includes a core with a plurality of slots. A plurality of electric conductors are positioned in the slots. Each of the plurality of electric conductors includes a U-turn portion extending between two in-slot portions and connection ends extending from the in-slot portions. The connection ends are positioned on an opposite end of the core from the U-turn portions. A plurality of insulation tubes are positioned in the plurality of slots. The in-slot portions of the electric conductors extend through the insulation tubes. | 09-20-2012 |
20120235616 | POSITION SENSING SYSTEM FOR A THREE (3) PHASE ELECTRIC MOTOR - A multi-phase electric motor including a housing, a stator mounted to the housing, a rotor rotatably mounted relative to the stator, and a position sensing system configured and disposed to output a signal representing a position of the rotor relative to the stator. The position sensing system includes a rotating member mounted relative to the rotor and a plurality of digital sensors mounted relative to the rotating member. At least two of the plurality of digital sensors are configured and disposed to generate a quadrature output signal. The plurality of digital sensors being configured and disposed to sense discrete portions of the rotating member to detect a position of the rotor relative to the stator. | 09-20-2012 |
20120235534 | CONDUCTOR INSULATION ARRANGEMENT FOR ELECTRIC MACHINE WINDING - An electric machine includes a core with a plurality of slots. A plurality of conductors are positioned in each of the plurality slots, with each slot including an equal number of conductors. At least one slot liner is also positioned in each of the plurality of slots. Each slot liner provides at least one slot liner channel in the associated slot, and each of the plurality of conductors extend through one of the slot liner channels. Differing numbers of slot liner channels are provided in the plurality of slots. Accordingly, all slots have the same number of conductors positioned therein, but all slots do not have the same number of slot liner channels. | 09-20-2012 |
20120194012 | Electric Machine Cooling System and Method - Some embodiments of the invention provide an electric machine module comprising an electric machine including a rotor assembly and a rotor hub. In some embodiments, the module can include a output shaft substantially circumscribed by the rotor hub and including at least one channel and at least one coolant outlet. A cavity can be formed by at least the output shaft and the rotor hub. Some embodiments can include a sleeve substantially circumscribing a portion of the output shaft with at least a portion of the sleeve positioned substantially within the cavity between the output shaft and the rotor hub. The sleeve can include at least one groove. | 08-02-2012 |
20120187783 | STATOR WINDING CONNECTION ARRANGEMENT - An electric machine a cylindrical stator core having an outer perimeter surface and an inner perimeter surface with a plurality of slots formed between the inner perimeter surface and the outer perimeter surface. The inner perimeter surface defines an inner cylindrical space for the stator that extends in an axial direction within the stator. The stator core is configured to retain a winding arrangement comprised of a plurality of conductor segments positioned in the plurality of slots of the stator core. The winding arrangement further includes a jumper extending into the inner cylindrical space and connecting two of the plurality of conductor segments. Accordingly, the jumper appears as a chord of a circular end shape of the stator core. | 07-26-2012 |
20120186869 | METHOD OF BLOCKING ELECTRO-MAGNETIC INTERFERENCE (EMI) IN AN ELECTRIC MACHINE AND APPARATUS - A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure. | 07-26-2012 |
20120183247 | ELECTRIC MACHINE WITH INTEGRATED BEARING TEMPERATURE SENSOR - An electric machine includes a housing and a shaft arranged within the housing. The shaft includes a first end portion and a second end portion. At least one bearing is mounted at one of the first end portion of the shaft and the second end portion of the shaft. A stator is mounted within the housing and a rotor is mounted relative to the shaft and rotatable relative to the stator. A temperature sensor is integrated into the housing at the at least one bearing. The temperature sensor includes a sensing element that detects a temperature of the at least one bearing. | 07-19-2012 |
20120181967 | PERMANENT MAGNET ELECTRIC MACHINE HAVING AN INTEGRATED MAGNETIC FLUX SENSOR - A permanent magnet electric machine that includes a housing, a stator mounted within the housing, a rotor assembly, a plurality of permanent magnets mounted within the rotor assembly, and a magnetic flux sensor arranged within the housing. The magnetic flux sensor includes a sensing surface configured and disposed to detect magnetic flux leaking from the rotor assembly. | 07-19-2012 |
20120181965 | ELECTRIC MACHINE HAVING AN INTEGRATED VIBRATION SENSOR - An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a vibration sensor arranged within the housing. The vibration sensor includes a sensing member configured and disposed to detect vibrations of the electric machine. | 07-19-2012 |
20120181884 | ELECTRIC MACHINE HAVING AN INTEGRATED COOLANT LEVEL SENSOR - An electric machine includes a housing having a coolant collection area, a stator mounted within the housing, a rotor assembly rotatably mounted within the housing relative to the stator, and a coolant level sensor arranged at the coolant collection area. The coolant level sensor includes a sensing surface configured and disposed to detect a level of coolant collected in the coolant collection area. | 07-19-2012 |
20120181883 | ELECTRIC MACHINE WITH INTEGRATED COOLANT TEMPERATURE SENSOR - An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a coolant system fluidly connected to the housing. The coolant system delivers a flow of coolant through the housing. A coolant temperature sensor is arranged within the housing and exposed to the flow of coolant. The coolant temperature sensor configured and disposed to detect a temperature of the coolant in the housing. | 07-19-2012 |
20120181882 | ELECTRIC MACHINE HAVING AN INTEGRATED ROTOR TEMPERATURE SENSOR - An electric machine includes a housing, a stator mounted within the housing, and a rotor rotatably mounted within the housing relative to the stator. The rotor includes a rotor lamination assembly having a plurality of laminations. A temperature sensor is arranged within the housing. The temperature sensor includes a sensing surface configured and disposed to detect a temperature of the rotor. | 07-19-2012 |
20120176006 | ELECTRIC MACHINE HAVING INTEGRATED RESOLVER - An electric machine that includes a stator and a rotor. The rotor includes a shaft and a lamination assembly coupled to the shaft and is configured and disposed to rotate relative to the stator, the rotor lamination assembly including a plurality of laminations that define an outer periphery having an outer surface and an inner surface. The electric machine also includes a resolver rotor coil at least partially radially inwardly disposed of the inner surface and formed in the rotor lamination assembly and a resolver stator located between the resolver rotor coil and the shaft. | 07-12-2012 |
20120129647 | GEAR SHOCK CONTROL MEMBER FOR A DRIVE TRAIN COMPONENT GEAR SET - A drive train component includes a housing having a plurality inner surfaces that collectively define an interior portion. A gear set is arranged within the interior portion. The gear set includes a first side and a second side. A gear shock control member is positioned between one of the first and second sides of the gear set and an adjacent component. The gear shock control member includes a plurality of pre-loaded biasing members that direct an axial force onto the gear set. | 05-24-2012 |
20120129645 | GEAR LASH CONTROL MEMBER FOR A DIFFERENTIAL GEAR SET AND METHOD OF ESTABLISHING GEAR LASH - A differential gear set including a gear housing and a first planet gear rotatably mounted to the gear housing and includes a first end portion having a plurality of planet gear teeth. A second planet gear is rotatably mounted to the gear housing and includes a first end portion having a plurality of planet gear teeth. A side gear is rotatably mounted in the gear housing and includes a plurality of side gear teeth that mechanically engage with the plurality of planet gear teeth of the first planet gear and the plurality of planet gear teeth of the second planet gear. A gear lash control member is interposed between the first and second planet gears and the side gear. The gear lash control member maintains a desired gear lash of the plurality of planet gear teeth and to the plurality of side gear teeth. | 05-24-2012 |
20120129644 | TRANSMISSION MEMBER INCLUDING AN ELECTRIC MOTOR HAVING AN INTEGRATED DIFFERENTIAL - A transmission member including a housing, a stator assembly arranged within the housing, and a rotor assembly rotatably mounted relative to the stator assembly within the housing. The rotor assembly includes a hub portion that defines, at least in part, a carrier. A differential gear assembly is arranged within the carrier. The differential gear assembly includes first and second planet gears driven by the carrier, and first and second side gears driven by the first and second planet gears. | 05-24-2012 |
20120129642 | ANTI-ROTATION PIN FOR A PLANETARY GEAR UTILIZING A TWO-PIECE CARRIER - A planetary gear set includes a ring gear having an inner diametric surface that defines an inner ring gear portion. A carrier assembly is arranged within the inner ring gear portion. The carrier assembly includes a carrier member having a carrier member body including a planet gear support surface and at least one carrier plate support member that extends substantially perpendicularly from the planet gear support surface. The at least one carrier plate support member includes a carrier plate support element having an opening. At least one planet gear pin extends from a first end portion arranged at the planet gear support surface to a second end portion, and at least one anti-rotation pin extends from a first end section arranged at the planet gear support surface through the opening in the carrier plate support element to a second end section. | 05-24-2012 |
20120129641 | LOCKING RING FOR A PLANETARY GEAR SET INCORPORATED INTO A TRANSMISSION MEMBER - A planetary gear set includes a carrier assembly. The carrier assembly includes a carrier member having a carrier member body that defines an inner carrier portion. The carrier member body includes a planet gear support surface and a carrier plate support member that extends substantially perpendicularly from the planet gear support surface. The carrier plate support member includes an edge portion having a mounting element. A carrier plate is arranged, at least in part, within the inner carrier portion at the edge portion. The carrier plate includes a carrier plate body having first and second opposing surfaces that define an outer edge section. The outer edge section includes a mounting member. A locking member is arranged in the mounting element and the mounting member to operatively coupling the carrier member and the carrier plate. | 05-24-2012 |
20120126660 | ROTOR LAMINATION COMPRESSION SLEEVE FOR AN ELECTRIC MACHINE - An electric machine including a stator, and a rotor lamination assembly configured and disposed to rotate relative to the stator. The rotor lamination assembly includes a plurality of laminations that define an outer diametric surface. A rotor lamination compression sleeve extends about the outer diametric surface of the rotor lamination assembly. The rotor lamination compression sleeve exerts a compressive radial force on the rotor lamination assembly. The rotor lamination compression sleeve is configured and disposed to expand when subjected to a centrifugal force while still maintaining a compressive radial force. | 05-24-2012 |
20120126650 | CONCENTRIC MOTOR POWER GENERATION AND DRIVE SYSTEM - An apparatus is provided and includes a hub, including first and second opposing faces, a first sidewall fixed at opposite ends thereof to the first and second opposing faces to define a first interior between the first and second opposing faces and a second sidewall fixed to one of the first and second opposing faces to define a second interior within the first interior, a first assembly, disposed within the second interior, to generate current from input mechanical energy and a second assembly, electrically coupled to the first assembly and disposed within the first interior, to generate mechanical energy from current associated with the current generated by the first assembly. | 05-24-2012 |
20120125149 | MOTOR STARTER INCLUDING AN ARMATURE HAVING AN INTEGRAL DRIVE SYSTEM - A motor starter includes a housing having an exterior surface and an interior surface that defines an interior portion, a field coil mounted to the interior surface of the housing, and an armature is supported within the housing and rotatable relative to the field coil. The armature includes a shaft having an exterior surface and a hollow interior. A commutator is operatively connected to the shaft, and a drive system is arranged within the hollow interior of the shaft. The drive system includes a gear system. An output shaft is operatively connected to the gear system. | 05-24-2012 |
20120124837 | METHOD OF ASSEMBLING A DIFFERENTIAL GEARSET - A method of assembling a differential gear set includes installing a first bushing into a carrier, installing a second bushing into the carrier, and inserting a first planet gear into an interior portion of the carrier. The first planet gear includes a first planet gear shaft. A second planet gear including a second planet gear shaft is inserted into the interior portion of the carrier. The first and second planet gear shafts are installed into the first and second bushings. A third planet gear including a third planet gear shaft is inserted into the interior portion of the carrier and a fourth plant gear including a fourth planet gear shaft is inserted into the interior portion of the housing. The third and fourth planet gear shafts are passed into corresponding bushing receptors in the carrier. Third and fourth bushings are installed on the third and fourth planet gear shafts. | 05-24-2012 |
20120112680 | ELECTRIC MACHINE SYSTEM INCLUDING AN ALTERNATING ELECTRIC CURRENT (AC) ELECTRIC MACHINE HAVING A SWITCH MODULE - An electric machine system includes an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing and a rotor is rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes at least one switch module having at least one switch member. The at least one switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A direct current (DC) power source is electrically connected to the stator through the switch assembly. A controller is operatively connected to the switch assembly. | 05-10-2012 |
20120112608 | ELECTRIC MACHINE HAVING AN INTEGRATED INVERTER - An electric machine system includes an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion, a rotor rotatably mounted relative to the stator, and a plurality of switch members are arranged within the switch portion. The plurality of switch members are electrically connected to the stator. A direct current power source is electrically connected to the plurality of switch members. A controller is arranged within a controller housing and electrically connected to the plurality of switch members. The controller housing is distinct from and remotely mounted relative to the AC electric machine. The controller is configured and disposed to activate select ones of the plurality of switch member to convert DC current between the DC power source and an AC current to operate the AC electric machine. | 05-10-2012 |
20120112576 | INVERTER FOR AN ELECTRIC MACHINE - An electric machine system including an alternating current (AC) electric machine having a machine housing, and a plurality of switch members arranged within a switch housing. The plurality of switch members are electrically connected to the AC electric machine. A direct current (DC) power source is electrically connected to the plurality of switch members. The DC power source generates a DC current. A controller is arranged within a control housing that is remote from the switch housing. The controller is electrically connected to the plurality of switch members and is configured and disposed to selectively activate select ones of the plurality of switch members in order to convert the DC current between the DC power source and an alternating current (AC) to operate the AC electric machine. | 05-10-2012 |
20120112573 | ELECTRIC MACHINE SYSTEM INCLUDING AN ALTERNATING CURRENT (AC) ELECTRIC MACHINE HAVING AN EXPANDABLE COOLANT MANIFOLD - An electric machine system including an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing, and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes a switch module having a switch member. The switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A cooling system that includes an expandable coolant manifold is arranged in the switch portion of the machine housing. The expandable coolant manifold is fluidly connected to the switch module. | 05-10-2012 |
20120112568 | COOLING SYSTEM FOR AN ELECTRIC MACHINE SYSTEM INCLUDING AN ALTERNATING CURRENT (AC) ELECTRIC MACHINE HAVING AN INTEGRATED SWITCH ASSEMBLY - An electric machine system includes an alternating current (AC) electric machine. The AC machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. A direct current (DC) power source is electrically connected to the stator through the switch assembly. A cooling system is fluidly connected to the AC electric machine. The cooling system directs a flow of coolant onto the switch assembly in the switch portion of the machine housing, and onto at least one of the stator and the rotor in the machine portion of the machine housing. | 05-10-2012 |
20120111650 | Drive System - A drive system package includes a housing. Located at the housing are a mechanical interface to output mechanical power, an electrical power connector receiver and a user interface. A motor vehicle includes a motor vehicle frame and one or more drive components. The motor vehicle further includes a drive system package having a housing. A mechanical interface is located at the housing and is operably connectable to the one or more drive components. The drive system package further includes an electrical power connector receiver and a user interface located at the housing. | 05-10-2012 |
20120068657 | ELECTRIC MACHINE SYSTEM INCLUDING AN ELECTRIC MACHINE HAVING SWITCHED STATOR WINDINGS - An electric machine system includes an electric motor. The electric motor includes a stator having a plurality of windings that define a number of phases. A plurality of switch members are operatively coupled to the plurality of windings. The plurality of switch members are no more than one less than three times the number of phases. A controller is operatively coupled to the plurality of switch members. The controller selectively changes a state of the plurality of switch members to establish one of a first electrical connection configuration of the plurality of windings and a second electrical connection configuration of the plurality of windings. | 03-22-2012 |
20120068656 | SWITCH MODULE FOR AN ELECTRIC MACHINE HAVING SWITCHABLE STATOR WINDINGS - An electric machine including a housing and a stator arranged within the housing. The stator includes a plurality of stator windings that define a number of phases. A switch module is mounted at the housing. The switch module includes a plurality of switch members that are operatively connected to the plurality of stator windings. The plurality of switch members are configured and disposed to selectively establish one of a first electrical connection configuration and a second electrical connection configuration of the plurality of stator windings. | 03-22-2012 |
20120068570 | PARALLEL PATH PHASE LEAD EXITS FROM ELECTRIC MACHINE - A stator winding for an electric machine includes two or more conductors defining one or more phases about the stator winding. Each phase includes at least two conductors of the two or more conductors arranged in an electrically switchable relationship. An end of each conductor of the two or more conductors extends to an exterior of the electric machine and is configured for independent electrical connection to a component at the exterior of the electric machine. An electric machine includes a stator having a stator winding including two or more conductors defining one or more phases about the stator winding including at least two conductors of the two or more conductors arranged in an electrically switchable relationship. An end of each conductor of the two or more conductors extends to an exterior of the electric machine for independent electrical connection to a component at the exterior of the electric machine. | 03-22-2012 |
20120065900 | LIFE MONITOR FOR ELECTRIC MACHINE - A method for monitoring remaining life of an electric machine for a motor vehicle includes sensing a temperature of a component of the electric machine at one or more time intervals. A percentage of life of the component consumed at each time interval is calculated and the percentages of life consumed are summed to determine a total percentage of life consumed. The total percentage of life consumed is compared to a selected threshold. A life monitor system for an electric machine for a vehicle includes a temperature sensor secured to a component of the electric machine. An engine control unit is operably connected to the temperature sensor and is configured to calculate a remaining life of the component of the electric machine compared to a selected threshold, based on temperature data from the temperature sensor. | 03-15-2012 |
20120062056 | ELECTRIC MACHINE INCLUDING A STATOR HAVING A STATOR SLEEVE AND METHOD OF COOLING A STATOR - An electric machine including a housing, and a stator mounted relative to the housing. The stator includes a body including a first end portion that extends to a second end portion and a plurality of stator windings that extend between the first and second end portions. A sleeve member is mounted to the stator and covers a portion of the stator windings at one of the first and second end portions. The sleeve member is configured and disposed to guide a coolant over the portion of the stator windings to remove heat from the stator. | 03-15-2012 |
20120062054 | PERMANENT MAGNET ROTOR FOR ELECTRIC MACHINE - A permanent magnet rotor assembly for an electric machine includes a rotor core including one or more axially-extending openings and one or more permanent magnets located in the one or more axially-extending openings defining one or more gaps between the one or more permanent magnets and the one or more axially-extending openings. One or more thermally-conductive bars are located in the one or more gaps to transfer thermal energy from an interior of the rotor assembly toward an axial end of the rotor assembly. | 03-15-2012 |
20120043836 | Disk Style Centrifugal Pump - An electric machine system includes an electric motor and an oil pump disposed within a housing. The oil pump is configured to disperse oil in a pattern about a rotational axis within the electric motor. A method for operating the electric machine system is also disclosed. | 02-23-2012 |
20120043835 | MATERIAL MATRIX FOR COOLING MEDIA ENHANCEMENT - An electric machine includes: a stator having stator windings; a rotor configured to interact electromagnetically with the stator; and a housing configured to house the stator and the rotor. A material matrix is disposed within the housing and in contact with the stator windings. The material matrix defines a plurality of passages configured for the cooling fluid to flow within to remove heat from the stator windings. | 02-23-2012 |
20120043809 | Auxiliary Device Using Primary Inverter Feeds - An electric machine system includes an electric motor, an auxiliary device configured to receive filtered electric power, and a filter. The filter is configured to receive electric power and to pass filtered electric power to the auxiliary device at a frequency not used for power conversion to rotational energy by the electric motor. A method for operating the electric machine system is also disclosed. | 02-23-2012 |
20120042665 | REJECT HEAT DRIVEN ABSORPTION COOLING CYCLE - An electric machine system includes: an electric motor; and an absorption cooling system driven by heat generated by the electric motor and configured to cool a primary cooling fluid that removes the heat from the electric motor to a temperature below an ambient temperature of an ultimate heat sink. A method for operating the electric machine system is also disclosed. | 02-23-2012 |
20120032540 | Phase Lead Connection for Parallel Path Electric Machine - A stator for an electric machine includes a stator winding located at a stator core. The stator winding has one or more phases, each phase including a single unitary conductor having at least two conductor segments arranged in an electrically parallel relationship. A connection portion is formed in the single unitary conductor between a first conductor segment and a second conductor segment of the at least two conductor segments to connect the conductor to an electrical component. | 02-09-2012 |
20120019095 | RADIAL PIN COUPLED HUB AND RIM ASSEMBLY - A rotor assembly includes a lamination and a hub. The hub includes an inner portion and an outer portion surrounding the inner portion and separated from it by an expansion gap. The rotor assembly also includes two or more connecting members coupling the inner portion to the outer portion, the connecting members having a first end and a second end. | 01-26-2012 |
20120013310 | Alternator Assembly With Opportunistic Voltage Regulation System - An electrical machine has been developed that opportunistically regulates the voltage supplied to the coil of the electrical machine. The electrical machine includes a stator winding, a rotatable electromagnet, and a voltage regulator. The voltage regulator is configured to control an output voltage of the electrical machine. The regulator is configured to vary the magnitude of the output voltage based at least in part on acceleration of the vehicle. | 01-19-2012 |
20120013225 | ELECTRIC MACHINE ALIGNMENT ADAPTER - An electric machine including a stator having a body provided with at least one alignment member, and a resolver positioned relative to the stator. The resolver includes at least one alignment element. An alignment adaptor is configured to receive each of the stator and the resolver. The alignment adaptor includes an alignment system that positions the alignment member and the alignment element to establish a desired alignment between the stator and the resolver. | 01-19-2012 |
20120013217 | MAGNETIC FLUX CARRYING SLEEVE MEMBER FOR AN ELECTRIC MACHINE - An electric machine including a housing and a stator arranged within the housing. The stator includes a body having a first end that extends to a second end through an intermediate portion. The intermediate portion includes an inner diametric surface and an outer diametric surface. A sleeve member is arranged on the outer diametric surface of the stator. The sleeve member includes body member having an inner diametric region that extends to an outer diametric region through an intermediate region. The sleeve member defines a flux carrying member having a magnetic flux flow path that passes magnetic flux from the stator to the outer diametric region. | 01-19-2012 |
20120013211 | ELECTRIC MOTOR HAVING A SELECTIVELY ADJUSTABLE BASE SPEED - An electric machine includes a stator mounted within the housing, and a transmission member mounted within the housing and surrounded at least in part by the stator. The transmission member includes a gear mechanism operatively coupled to an output shaft. The transmission mechanism is rotatable relative to the stator. | 01-19-2012 |
20120013207 | STATOR SLEEVE FOR AN ELECTRIC MACHINE AND METHOD OF ESTABLISHING A COOLANT CAVITY ABOUT A STATOR FOR AN ELECTRIC MACHINE - An electric machine including a housing, and a stator mounted within the housing. The stator includes an outer perimetric surface and an inner perimetric surface. A rotor is mounted, at least in part, within the inner perimetric surface of the stator. The rotor is rotatable relative to the stator. A stator sleeve extends about the stator. The stator sleeve includes a first sleeve portion and a second sleeve portion. The first sleeve portion includes a first diametric edge that extends to a second diametric edge, and the second sleeve portion includes a first diametric edge section that extends to a second diametric edge section. The stator sleeve is configured and disposed to establish a coolant cavity about the outer perimetric surface of the stator. | 01-19-2012 |
20110316369 | ROTOR FAN FOR AN ELECTRIC MACHINE - An electric machine includes a rotor. The rotor includes a body having a number of pole members, a central hub, and a plurality of mounting members. The plurality of mounting members are fewer than half the number of pole members. A fan member is mounted to the rotor. The fan member includes a number of fan blades that project outward from a hub portion. A plurality of mounting elements are provided on select ones of the number of fan blades. The plurality of mounting members engage respective ones of the plurality of mounting elements to attach the fan member to the rotor. | 12-29-2011 |
20110298319 | Electric Machine Cooling System and Method - Embodiments of the invention provide an electric machine module including a housing defining a machine cavity. In some embodiments, an electric machine can be positioned within the machine cavity and include a rotor hub coupled to rotor laminations. The rotor hub can include first and second axial ends and the rotor laminations can include a recess. In some embodiments, the recesses can be aligned to define a portion of a plurality of coolant channels that can be in fluid communication with the machine cavity. In some embodiments, the rotor hub can include first and second rotor hub inlets in fluid communication with at least a portion of the coolant channels. The first and the second rotor hub inlets can be adjacent to the axial ends of the rotor hub. In some embodiments, the coolant channels are in fluid communication with the rotor hub inlets are not the same coolant channels. | 12-08-2011 |
20110298315 | Electric Machine Cooling System and Method - Embodiments of the invention provide an electric machine module including a housing. In some embodiments, the housing can include a sleeve member coupled to at least one end cap. The housing can include an inner wall at least partially defining a machine cavity, a coolant sump, and at least one coolant channel positioned between the inner wall and an outer wall of the housing. In some embodiments, the coolant channel can be in fluid communication with the coolant sump. In some embodiments, an electric machine can be positioned in the machine cavity. The electric machine can comprise a stator assembly including stator end turns and a rotor assembly. In some embodiments, a coolant jacket can be at least partially defined by the housing and can be positioned so that to at least partially circumscribe a portion of the stator assembly. | 12-08-2011 |
20110285241 | ROTOR LAMINATION ASSEMBLY - An electric machine includes a rotor lamination assembly having a lamination member formed from a material having a first yield strength. The lamination member includes a first bridge portion having a first width, and a first bridge zone having a first thickness. The rotor lamination assembly also includes at least one lamination section having a second bridge zone having a second thickness. The second thickness is greater than the first thickness. The rotor lamination assembly further includes at least one lamination element formed from a second material having a second yield strength that is higher than the first yield strength, and at least one lamination component. The at least one lamination component includes a second bridge portion having a second width. The second width is greater than the first width. | 11-24-2011 |
20110285222 | Sleeve Member for an Electric Machine - Embodiments of the invention provide an electric machine module including a module housing. The module housing can include a sleeve member coupled to at least one end cover and can define a machine cavity. In some embodiments, the sleeve member can include an inner perimeter and can be coupled to a stator assembly of an electric machine. In some embodiments, the electric machine can be positioned within the machine and at least partially enclosed by the module housing. In some embodiments, a coolant jacket can be defined by at least a portion of the sleeve member and at least a portion of the stator assembly. | 11-24-2011 |
20110285221 | Stator Winding Assembly and Method - An electrical device includes a plurality of stacked laminates that form a tubular stator portion, a cooling passage partially defined by orifices formed in the plurality of stacked laminates, a housing including a cavity further defining the cooling passage, the cooling passage defining a fluid flow path parallel to a rotational axis of the stator portion, a sump portion communicative with the cooling passage, the sump portion including a cavity defined by the stator portion and the housing member. | 11-24-2011 |
20110283529 | APPARATUS FOR LOADING STATOR WINDINGS INTO A STATOR CORE - An apparatus for loading stator windings into a stator core includes an arbor member including a body having an outer diametric portion and a central axis. The outer diametric potion includes a plurality of slots. The apparatus also includes a guide track having a first end that extends to a second end through a slide portion. The first end is positioned adjacent the outer diametric portion of the arbor member. At least one of the guide track and the arbor member is selectively positionable to guide slot segment portions of a stator winding into predetermined ones of the plurality of slots. | 11-24-2011 |
20110283523 | METHOD FOR LOADING STATOR WINDINGS INTO A STATOR CORE - A method of loading stator windings into a stator core includes guiding a first stator winding including a plurality of slot segment portions along at least one guide track towards an arbor member having a plurality of slots, inserting one of the plurality of slot segment portions of the first stator winding into one of the plurality of slots, and guiding a second stator winding including a plurality of slot segment portions along the at least one guide track towards the arbor member. The method also includes indexing one of the at least one guide track and the arbor member to position another of the plurality of slots adjacent the at least one guide track, inserting one of the plurality of slot segment portions of the second stator winding into another of the plurality of slots, rotating the arbor member, and feeding a plurality of slot segment portions into remaining ones of the plurality of slots. | 11-24-2011 |
20110279203 | INTEGRATED MAGNETIC SWITCH ASSEMBLY FOR A VEHICLE STARTER SOLENOID AND METHOD OF FORMING AN INTEGRATED MAGNETIC SWITCH ASSEMBLY - An integrated magnetic switch assembly includes a winding assembly portion having a housing, and a cover assembly mounted to the housing. The cover assembly includes at least one rivet terminal and at least one power terminal The at least one rivet terminal includes a body that extends through the cover assembly. The body has a first end that extends to a second end, and an opening that includes a first diameter that extends from the first end to the second end. A sealing member is positioned at the first end of the body about the opening of the at least one rivet terminal. The sealing member includes an opening having a second diameter that is smaller than the first diameter. A sealing element is positioned between the at least one power terminal and the cover assembly. | 11-17-2011 |
20110273121 | Electric Machine Component Temperature Monitoring - Embodiments of the invention provide an electric machine module including a module housing. In some embodiments, the module housing can at least partially define a machine cavity into which an electric machine can be positioned. The electric machine can include a rotor assembly comprising a plurality of laminations and a least one magnet positioned substantially within the rotor assembly. In some embodiments, at least one temperature sensor can be operatively coupled to, and in thermal communication with, a portion of the rotor assembly. The temperature sensor can be configured to sense a temperature of the rotor assembly. In some embodiments, at least one transmitter can be in communication with the temperature sensor and can transmit a signal from the temperature sensor to a receiver. In some embodiments, the receiver can be coupled to the module housing and in communication with a controller. | 11-10-2011 |
20110273049 | ROTOR LAMINATION ASSEMBLY - An electric machine includes a stator, and a rotor lamination assembly configured and disposed to rotate relative to the stator. The rotor lamination assembly includes at least one lamination member including a body member having an outer diametric edge, and at least one magnet receiving member. The at least one magnet receiving member includes a first end that extends to a second end. The second end establishes an interruption zone in the outer diametric edge. | 11-10-2011 |
20110273047 | ROTOR LAMINATION ASSEMBLY - An electric machine includes a stator, and a rotor lamination assembly configured to rotate relative to the stator. The rotor assembly includes at least one lamination member that includes a body having an inner diametric edge that extends to an outer diametric edge, and at least one magnet receiving member. The at least one magnet receiving member is formed in the body and includes a first end that extends to a second end. The second end is spaced from the outer diametric edge to form a bridge portion. The at least one lamination member includes at least one stress concentration element positioned between the inner diametric edge and the outer diametric edge. The at least one stress concentration element is configured and disposed to reduce stress in the bridge portion. | 11-10-2011 |
20110273040 | Electric Machine Cooling System and Method - Some embodiments of the invention provide an electric machine including a rotor assembly. In some embodiments, the rotor assembly can include a plurality of rotor laminations including at least one first aperture positioned through a portion of the rotor laminations. In some embodiments, the first apertures can form at least one magnet channel when the rotor assembly is substantially assembled. At least one permanent magnet can be positioned in each of the magnet channels. In some embodiments, at least one second aperture can be positioned through a portion of some of the laminations, along a Q-axis, and adjacent to the at magnet channel. Also, the second apertures can be configured and arranged to form at least one first coolant channel when the rotor assembly is substantially assembled. | 11-10-2011 |
20110273039 | Electric Machine Cooling System and Method - Embodiments of the invention provide an electric machine module including a module housing, which can at least partially define a machine cavity. In some embodiments, an electric machine can include a stator assembly and a rotor assembly and can be positioned in the machine cavity. In some embodiments, the module housing can include a coolant transport network, which can include at least one passage in fluid communication with at least one first annulus and at least one second annulus. In some embodiments, the first annulus can be substantially axially adjacent to an axial end of the stator assembly and the second annulus can be substantially axially adjacent to an axial end of the rotor assembly. In some embodiments, the annuli can include a plurality of annulus apertures. | 11-10-2011 |
20110167622 | METHOD AND APPARATUS FOR LOADING STATOR WINDINGS INTO A STATOR CORE - An apparatus for loading stator windings into a stator core includes an arbor member including a body having a central axis and an outer diametric portion provided with a plurality of slots. An insertion element is rotatably mounted adjacent the arbor member. The insertion element includes a plurality of slot elements that are configured to register with the plurality of slots. A loading member is rotatably mounted adjacent the insertion element. The loading member includes a plurality of slot members that are configured to register with the plurality of slot elements. The loading member is selectively operated to receive a stator winding into one of the plurality of slot members and transfer the stator winding into one of the plurality of slot elements. The at least one insertion element is selectively operated to transfer the stator winding into one of the plurality of slots of the arbor member. | 07-14-2011 |
20110148243 | STATOR CORE FOR AN ELECTRIC MACHINE - A stator includes a body portion having an outer portion and an inner portion that defines an interior region, a plurality of stator teeth members extending from the inner portion into the interior region, and at least one continuous conductor wound around select ones of the plurality of stator teeth members to form at least one pole. Each of the plurality of stator teeth members including a number of wraps of the at least one continuous conductor. The at least one continuous conductor including a number of twists that is fewer than the number of wraps. | 06-23-2011 |
20110115321 | ELECTRIC MOTOR AND PLANETARY GEAR ASSEMBLY - An electric motor assembly includes a stator defining a first interior space, a rotor positioned within the first interior space and configured for rotation relative to the stator, the rotor defining a second interior space, and a planetary gear assembly associated with the rotor and at least partially positioned within the second interior space. | 05-19-2011 |
20110115320 | REVERSIBLE PLANETARY GEAR ASSEMBLY - A planetary gear assembly includes a ring gear configured for connection to a rotor of an electric motor when in a first position and configured for connection to a housing of the electric motor when in a second position, a sun gear configured for connection to the housing when the ring gear is in the first position and configured for connection to the rotor when the ring gear is in the second position, and a plurality of planet gears configured to mesh with the ring gear and the sun gear. | 05-19-2011 |
20110114399 | TRACTION MOTOR AND PLANETARY GEAR ASSEMBLY - A vehicle includes a chassis, a traction member associated with the chassis, and a drive system associated with the chassis and the traction member comprising an electric traction motor, a planetary gear assembly coupled to the electric traction motor, the planetary gear assembly comprising an output member coupled to the traction member, wherein rotation of the output member provides a drive torque for the traction member. | 05-19-2011 |
20110072652 | METHOD OF WINDING A PLURALITY OF STATOR TEETH OF A SEGMENTED STATOR CORE - A winding apparatus includes a mounting fixture configured to support a plurality of stator teeth. The mounting fixture is configured to rotate about an axis defined by each of the plurality of stator teeth. A plurality of stator tooth holding elements are connected to the mounting fixture. The plurality of stator tooth holding elements retain a select one of the plurality of stator teeth relative to the mounting fixture. The mounting fixture is selectively rotated about the central axis of at least one of the plurality of teeth to apply wraps of wire to the one of the plurality of stator teeth while at the same time rotating others of the plurality of stator teeth. A wire guiding member is supported by the mounting fixture. The wire guiding member is configured and disposed to establish a desired length of wire between adjacent ones of the plurality of stator teeth. | 03-31-2011 |
20110031842 | COMPONENT FOR AN ELECTRIC MACHINE - A component for an electric machine includes a spool having a main body portion provided with a first end portion that extends substantially uninterrupted to a second end portion through an intermediate portion. A plurality of mounting elements are provided on the first end portion. A star member is operatively connected to the spool. The star member includes a main body, a plurality of flap members that extend from the main body and collectively define a central opening, and a plurality of mounting members that extend into the central opening. The plurality of mounting members engage with corresponding ones of the plurality of mounting elements to detachably mount the star member to the first end portion of the spool. | 02-10-2011 |
20100253164 | STATOR ASSEMBLY INCLUDING A TERMINAL BLOCK FOR AN ELECTRIC MACHINE - An electric machine includes a housing having an outer surface and an inner surface that defines an interior portion. The housing also includes a connection zone having a first end portion that extends from the outer surface to a second end portion that is exposed to the interior portion. The connection zone includes a connection passage. A terminal block extends through the connection passage. The terminal block includes a non-electrically conductive member that is sealed against the connection passage, and an electrically conductive member covered by the non-electrically conductive member. The electrically conductive member includes a first end section that extends to a second end section through an intermediate section. The first end section has a first connection zone and the second end section has a second connection zone. The second connection zone is at an angle relative to the first connection zone. | 10-07-2010 |
20100243785 | METHOD OF WINDING AN ELECTRIC MOTOR CORE MEMBER - A method of winding an electric motor core member includes continuously winding a single conductor about a portion of an electric motor core member, and separating the single, continuously wound conductor into multiple phase windings. | 09-30-2010 |
20100231180 | Alternator Regulator With Automatic Regulation Dependent on System Voltage - An alternator configured for use in a vehicle comprises a stator having a plurality of stator windings. A rotatable field coil is positioned adjacent to the stator within the alternator. A field driver circuit is configured to deliver an electric current to the field coil. A voltage sensor is configured to detect a battery voltage. A controller in the alternator is configured to execute either a first field current control program or a second field current control program depending at least in part upon the detected battery voltage. The first field current control program is configured to control the electric current delivered to the field coil in a 12 volt vehicle power system. The second field current control program is configured to control the electric current delivered to the field coil in a 24 volt vehicle power system. | 09-16-2010 |
20100143031 | MECHANICAL FASTENER HAVING A THREAD STAKING MECHANISM - A mechanical fastener includes a main body having an outer diametric portion and an inner diametric portion and a plurality of threads provided on at least one of the outer and inner diametric portions. The mechanical fastener further includes at least one staking mechanism formed in the main body at the at least one of the outer and inner diametric portion. The at least one staking mechanism extends into and bisects at least a portion of the plurality of threads. | 06-10-2010 |
20100141210 | ALTERNATOR FOR CHARGING MULTIPLE ELECTRIC STORAGE DEVICES - An alternator includes a body portion housing a charging circuit. A voltage regulator is mounted to the body portion and electrically coupled to the charging circuit. The voltage regulator is configured and disposed to output at least one charging current. An isolator is mounted to the body portion and electrically coupled to the charging circuit and the voltage regulator. The isolator is configured and disposed to be electrically coupled to at least two batteries with the isolator independently passing the at least one charging current to each of the first and second batteries. | 06-10-2010 |
20100141101 | SENSOR INCLUDING AN ANTI-ROTATION MECHANISM - A sensor assembly includes a main body having an outer wall member, an inner wall member, and an intermediate portion. The main body including a central opening defined by the inner wall member. The sensor assembly further includes at least one anti-rotation mechanism formed on the inner wall member. The at least one anti-rotation mechanism is adapted to deflect radially toward the outer wall member upon engagement with a component to be sensed. Upon deflection, the at least one anti-rotation mechanism fixedly secures the sensor assembly to the component to be sensed. | 06-10-2010 |
20100141082 | BRUSH HOLDER ASSEMBLY FOR A DYNAMO-ELECTRIC MACHINE - A brush holder assembly for a dynamo-electric machine includes a brush fixture snap-fittingly secured to a shielding fixture. A brush member is moveably mounted within the brush fixture and includes a recessed region, and a shunt member. The shunt member includes a first end operatively connected to the brush member at the recessed region that extends through an intermediate region to a second end. A constant force spring is operatively connected between the second end section of the brush and the brush fixture. The brush holder assembly also includes a shunt retainer mounted in the brush fixture abutting the brush member. The shunt retainer includes a first leg portion, a second leg portion and a base portion. The shunt retainer is configured to maintain proper alignment of the constant force spring and prevent entanglement of the shunt member. | 06-10-2010 |
20100141062 | Rotating Directional Coolant Spray for Electric Machine - Disclosed is a rotor for a fluid cooled electric machine including a rotor shaft rotably located at a central axis and a plurality of rotating coolant passages extending outwardly from the rotor shaft to direct a flow of coolant to a desired impingement location on the electric machine thereby removing thermal energy from the impingement location. Further disclosed is a fluid cooled electric machine including a plurality of coolant passages each including at least one coolant passage inlet and at least one coolant passage outlet, the plurality of coolant passages configured to rotate about the central axis and direct a flow of coolant therethrough to a desired impingement location thereby removing thermal energy from the impingement location. | 06-10-2010 |
20100139896 | LIQUID COOLED STATOR TERMINAL BLOCK FOR AN ELECTRIC MACHINE - An electric machine including a housing having an outer surface and an inner surface that defines an interior portion. The housing includes a connection zone. A fluid circuit passes, at least in part, through the housing. The fluid circuit includes an inlet portion and an outlet portion. A stator assembly is arranged within the interior portion of the housing. The stator assembly includes at least one connector lead, and a terminal block extending through the housing. The terminal block includes a non-electrically conductive member that is sealed against the housing. The non-electrically conductive member includes a fluid cavity. At least one electrically conductive member is covered, at least in part, by the non-electrically conductive member. The fluid cavity guides a fluid along a portion of the at least one electrically conductive member to absorb heat. | 06-10-2010 |