A starter system including a motor, a solenoid assembly having a solenoid switch, a pinion rotated by the motor and moveable into an engaging position in which an engine may be cranked and the solenoid switch is closed to energize the motor from an electric power source, and relay switch regulated by a controller and closed to apply electrical power to the solenoid assembly for actuating the solenoid switch. The controller repeatedly opens and closes relay switch during a starting operation if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after electrical power is applied to the solenoid assembly, whereby electrical power applications to the solenoid assembly are automatically repeated during a starting operation to correct “click-no-crank” events and prevent prolonged power application to the solenoid assembly. A related method is also disclosed.
F02N 11/08 - Circuits specially adapted for starting of engines
F02N 15/06 - Gearing between starting-engines and started enginesEngagement or disengagement thereof the gearing including disengaging toothed gears the toothed gears being moved by axial displacement
An electric machine including a housing, and a stator mounted to the housing. The stator includes a plurality of laminations, a first end turn and a second end turn. A rotor shaft extends through the housing. A hybrid rotor module is coupled to the rotor shaft. The hybrid rotor module includes a clutch basket having a rotor carrier. The clutch basket houses one or more clutch assemblies. A rotor is mounted to the rotor carrier, and one or more openings are formed in the rotor carrier. The one or more openings direct coolant onto at least one of the stator, the first end turn, and the second end turn.
An electric machine (50) including a rotor (52) and a stator (64) and having a first winding (70). The stator slots (68) define a plurality of layer positions (98, 100) wherein each of the layer positions is at a different radial distance from the axis (56). There is an odd number of select stator slots (68a) wherein for two slot segments disposed in different layer positions, a pair of end loops (96a, 96b; 96c, 96d) connect each of the slot segments with another slot segment in a different slot that is in the same layer position. In some embodiments, at least 60 percent of the end loops connect slot segments that are disposed in different layer positions. For some embodiments, only a single select stator slot (68a) is provided in each winding with the end loops being positioned to reduce spatial conflicts.
An electric machine (20) having a rotor (22), stator (26) and at least one winding (30). The winding defines a first lead (36) having a conductive core (48) and an electrically insulative exterior layer (46). A connector (50, 70) engaged with the first lead includes a plurality of projections (60, 82) that pierce the exterior layer of the first lead to engage the conductive core. The connector may be C-shaped (50) having a spine (54) and first and second arms (56) with first and second bend lines (58) respectively disposed between the spine and the two arms. Alternatively, the connector may be U-shaped (70) having a spine (72) and first and second arms (74, 76) wherein a bend line (78) and a central opening (80) are disposed between the two arms. The first lead extends through the central opening and is grippingiy engaged by the connector between the first and second arms. The connector may also be used to securely engage an uninsulated terminal (52).
A starter system including a motor, a solenoid assembly having a solenoid switch, a pinion rotated by the motor and moveable into an engaging position in which an engine may be cranked and the solenoid switch is closed to energize the motor from an electric power source, and relay switch regulated by a controller and closed to apply electrical power to the solenoid assembly for actuating the solenoid switch. The controller repeatedly opens and closes relay switch during a starting operation if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after electrical power is applied to the solenoid assembly, whereby electrical power applications to the solenoid assembly are automatically repeated during a starting operation to correct “click-no-crank” events and prevent prolonged power application to the solenoid assembly. A related method is also disclosed.
F02N 15/06 - Gearing between starting-engines and started enginesEngagement or disengagement thereof the gearing including disengaging toothed gears the toothed gears being moved by axial displacement
An alternator includes a housing, and a stator fixedly mounted relative to the housing. The stator includes a stator winding. The stator winding includes at least five stator leads extending from the stator in an arc that is less than about 90°. A terminal assembly is mounted to an outer surface of the housing and connected with the at least five stator leads. The terminal assembly includes a body formed from a non-electrically conductive material, and a plurality of conductive members at least partially covered by the body. The plurality of conductive members is associated with the stator winding. Each of the plurality of conductive members includes plurality of input connectors spread out along the body in an arc that is greater than 90°.
A starter system including a motor, a solenoid assembly having a solenoid switch, a pinion rotated by the motor and moveable into an engaging position in which an engine may be cranked and the solenoid switch is closed to energize the motor from an electric power source, and relay switch regulated by a controller and closed to apply electrical power to the solenoid assembly for actuating the solenoid switch. The controller repeatedly opens and closes relay switch during a starting operation if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after electrical power is applied to the solenoid assembly, whereby electrical power applications to the solenoid assembly are automatically repeated during a starting operation to correct "click-no-crank" events and prevent prolonged power application to the solenoid assembly. A related method is also disclosed.
An internal combustion engine includes a ring gear having a plurality of ring gear teeth. Each of the plurality of ring gear teeth includes a leading edge surface and a trailing edge surface. A starter motor is mounted to the internal combustion engine. The starter motor includes a pinion gear having a plurality of pinion gear teeth configured and disposed to selectively engage with the plurality of ring gear teeth. Each of the plurality of pinion gear teeth includes a leading edge surface portion and a trailing edge surface portion. The pinion gear is configured and disposed to engage with the ring gear while the ring gear is coasting. At least one of the trailing edge surface of each of the plurality of ring gear teeth and the leading edge surface portion of each of the plurality of pinion gear teeth includes a chamfer.
F02N 11/02 - Starting of engines by means of electric motors the motors having longitudinally-shiftable rotors
F16H 1/06 - Toothed gearings for conveying rotary motion without gears having orbital motion involving only two intermeshing members with parallel axes
An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a cooling tower having first and second axial ends and a central axis. The cooling tower includes a metallic first wall extending about the central axis and defining radially inner and outer first wall surfaces. An axially extending air flow passage extends through the cooling tower. Spaced metallic ribs traverse the air flow space and are in conductive thermal communication with the radially inner first wall surface. A plurality of circumferentially distributed power electronics devices are in conductive thermal communication with the cooling tower and secured to the radially outer first wall surface to thereby provide a heat sink for the power electronics devices. Electronic control circuitry is operatively connected to and substantially surrounded by the power electronics devices. An electric machine with such an electronic package is also disclosed.
H02K 9/02 - Arrangements for cooling or ventilating by ambient air flowing through the machine
H02K 5/22 - Auxiliary parts of casings not covered by groups , e.g. shaped to form connection boxes or terminal boxes
B60K 6/26 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the motors or the generators
An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.
H02K 5/22 - Auxiliary parts of casings not covered by groups , e.g. shaped to form connection boxes or terminal boxes
B60K 6/26 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the motors or the generators
An electronic package connectable to an electric machine. The electronic package includes a support structure with a first axial end engaged with the electric machine. The support structure circumscribes the central axis and defines radially inner and outer wall surfaces. Power modules are disposed on and circumferentially distributed about the radially outer wall surface and include a power electronics device. Each module includes a phase terminal coupled with the power electronics device and disposed radially outwardly of the radially outer wall surface. The support structure defines a plurality of voids extending between the radially inner and outer wall surfaces. Each of the power modules are positioned proximate a separate one of the voids. Each void has a phase lead extending therethrough. Each phase lead is connected to a phase terminal and conductively couples it with a stator winding. An electric machine having an electronic package is also disclosed.
H02K 5/22 - Auxiliary parts of casings not covered by groups , e.g. shaped to form connection boxes or terminal boxes
B60K 6/26 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the motors or the generators
12.
AXIALLY EXTENDING ELECTRIC MACHINE ELECTRONICS COOLING TOWER
An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a cooling tower having first and second axial ends. The cooling tower includes a metallic wall defining radially inner and outer wall surfaces and extending about the package central axis. The radially inner wall surface defines an axially extending air passage through the cooling tower with an inlet proximate the first axial end. Spaced metallic ribs are in conductive thermal communication with the radially inner wall surface traverse and the air passage. Power electronics devices are attached in conductive thermal communication to the radially outer wall surface. The cooling tower provides a heat sink for the power electronics devices with a primary cooling path for each of the power electronics device extending radially inwardly to the cooling tower. An electric machine including such an electronic package is also disclosed.
H02K 9/02 - Arrangements for cooling or ventilating by ambient air flowing through the machine
H02K 5/22 - Auxiliary parts of casings not covered by groups , e.g. shaped to form connection boxes or terminal boxes
B60K 6/26 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the motors or the generators
13.
BI-DIRECTIONAL MOSFET COOLING FOR AN ELECTRIC MACHINE
A power module for an electric machine. The power module includes a thermally conductive base having opposite first and second surfaces. The first surface is adapted for mounting the power module in conductive thermal communication with a heat sink. A MOSFET superposes the base second surface and is in conductive thermal communication with the base. A MOSFET driver superposes the base second surface and is operatively connected to the MOSFET. The transference from the power module of heat generated by the MOSFET and the MOSFET driver from the power module is directed along a primary cooling path to the heat sink through the base and a secondary cooling path to ambient air. The primary and secondary cooling paths are separate from each other. An electronics package and an electric machine including a power module are also disclosed.
An electronic package adapted for connection to a rear frame member of an electric machine of liquid and/or air-cooled type. The electronic package includes a cooling tower having opposite first and second axial ends spaced along a package central axis. The cooling tower includes a metallic wall extending about the package central axis to define a radially outer wall surface. The cooling tower is at ground potential and defines a heat sink. The electronic package also includes a plurality of power modules mounted in conductive thermal communication to the cooling tower at positions on the radially outer wall surface. Heat transference to the cooling tower from each power module occurs along a respective primary cooling path. Transference along the primary cooling paths of heat from the cooling tower includes thermal convection to air and/or liquid. An electric machine of liquid and/or air-cooled type including an electronic package is also disclosed.
H05K 7/20 - Modifications to facilitate cooling, ventilating, or heating
B60R 16/02 - Electric or fluid circuits specially adapted for vehicles and not otherwise provided forArrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric
15.
METHOD FOR COMPENSATING ALTERNATOR REGULATION TO CONTROL REMOTE BATTERY VOLTAGE UTILIZING ADAPTIVE VARIABLE
A method for compensating for alternator to battery voltage drop in charging systems lacking external remote sensing capabilities and utilizing serial communications. A controller utilizes an adaptive variable for determining an alternator output voltage setpoint that compensates for battery cable voltage losses, and adjusting the setpoint to achieve substantially constant battery voltage of the entire range of alternator loads.
H02J 7/14 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
16.
SYSTEM OF PARALLEL-CONNECTED GENERATORS AND METHOD FOR LOAD SHARE BALANCING THEREIN USING A SERIAL COMMUNICATION NETWORK
A parallel generator system wherein a portion of the electrical load of at least one generator unit is incrementally transferred to at least one other generator unit by the controller on the basis of an indication that the operating stresses of the generator units are disallowably unbalanced, whereby load share balancing tending towards equalization of operating stresses amongst the plurality of generator units occurs over the system service life. Also, a method for load share balancing in a parallel generator system which determines whether the operating stress levels of at least two generator units are disallowably unbalanced by comparing operating stress indicators of the generator units with that of a master generator unit, and incrementally transferring portions the electrical load between at least two generator units on the basis of the comparative evaluation, whereby load share balancing occurs tending to equalize the generator unit operating stress levels.
A wire forming apparatus comprises a first rack moveable relative to a second rack in a first direction. Multiple forming structures are provided on the first rack and the second rack. The plurality of forming structures include a first plurality of forming structures configured to move relative to the first rack in a second direction, and a second plurality of forming structures configured to move relative to the second rack in the second direction. A plurality of are actuators are configured to move the first rack relative to the second rack, move the first plurality of forming structures relative to first rack, and move the second plurality of forming structures relative to the second rack.
H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
H01F 41/04 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformersApparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils or magnets for manufacturing coils
An electric machine comprises 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 first fingers extending from a first end member with an opening between each of the plurality of first fingers. The second claw-pole segment includes a plurality of second fingers extending from a second end member with an opening between each of the plurality of second fingers. A plurality of magnets are positioned on the rotor, each of the plurality of magnets positioned between a pair of first and second fingers. A molded plastic insert is positioned on the rotor, the molded plastic insert positioned in one of the openings and extending over an outer surface of each of the plurality of magnets.
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.
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.
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.
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.
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.
An electric machine 20 that includes a stator core 34 having at least one slot 40 and a winding 42 in the slot 40. An elongate cooling conduit 46 defines at least one projecting bend 48 that is positioned in the slot 40. The projecting bend 48 has first and second axially extending legs 50, 52 and an intermediate section 54. Coolant is conveyed through a first axial end opening 39 of the slot within the first leg 50 and then sequentially conveyed through the intermediate section 54 and out the first axial end opening 39 within the second leg 52. The projecting bend 48 is in thermal communication with at least one of the winding 42 and the stator core 34. A method of manufacture is also disclosed and may include bending a conduit 46 having a uniform wall thickness 56 and cross-section to form a plurality of projecting bends 48. The method may also include simultaneously inserting the projecting bends 48 into respective slots 40 from one end of the stator core 34.
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.
A method of performing active vibration damping in a front end accessory drive (FEAD) system of an automobile using an alternator of the FEAD system and an alternator are described. The method includes determining a resonance to be counteracted, determining a counteracting forcing function to counteract the resonance, and determining a duty cycle change to apply to a field voltage to obtain an output voltage with the counteracting forcing function, wherein the field voltage results in a field current supplied to a rotor that causes a stator to generate the output voltage. The method also includes implementing the duty cycle change for a period of time.
A solid-state switch includes a plurality of transistors connected in parallel and a plurality of fuses. Each fuse is connected in series with a separate one of the plurality of transistors. A combination of current ratings of the plurality of fuses is greater than a load current of a load connected to the plurality of transistors and the plurality of fuses, and a current rating of each separate fuse of the plurality of fuses is less than the load current.
H03K 17/08 - Modifications for protecting switching circuit against overcurrent or overvoltage
H03K 17/687 - Electronic switching or gating, i.e. not by contact-making and -breaking characterised by the use of specified components by the use, as active elements, of semiconductor devices the devices being field-effect transistors
An electric machine having a stator, a rotor and a housing assembly with two end caps and inner and outer axially extending members. Ribs on one housing member engage the other housing member in an interstitial space and define axially extending fluid path segments. The liquid coolant path may be serpentine. The ribs may have a width greater than the radial thickness of the sleeve portion from which they extend. Fasteners can attach the end caps to the enlarged width ribs. The inner and outer housings are advantageously extrudable. An electronic component can be thermally coupled with an end cap and disposed radially inward and axially proximate a plurality of end turn fluid passages. The electronic component may be at least partially axially positioned between the distal limit of the stator windings and the axial limit of the serpentine path. The end caps may also support bearing assemblies.
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.
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.
H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
F04D 29/28 - Rotors specially adapted for elastic fluids for centrifugal or helico-centrifugal pumps
A starter assembly adapted for use with an engine having a flywheel and electronic control unit. The starter includes a motor, magnetic field source and a pinion gear engageable with the flywheel. An internal power train transmits torque from the armature to the pinion gear and includes a gear set dividing the internal power train into a first segment with the armature and a second segment with the pinion gear. During operation the first segment has a faster rotational speed than the second segment. A speed sensor senses the speed of the first segment and communicates it to the electronic control unit. The starter assembly can be used in a vehicle with an automatic start-stop function and facilitates the synchronizing of the pinion gear and flywheel speeds when restarting the engine. The speed sensor can take various forms and is advantageously supported on the field frame assembly proximate the commutator.
A method for controlling an engine starter system (20) including a starter (24) capable of being controlled by an electronic control unit (28) and having an electric motor (40) and a pinion (44) coupled together for transferring rotational torque from the motor (40) to the pinion (44) when the motor (40) is activated; controlling activation of the motor (40) with an electronic control unit output motor signal in response to an engine speed input signal; determining the pinion (44) speed in an open loop manner based solely on the time since activation of the motor (40) and the voltage applied to the motor (40); and selectively moving the pinion (44) between a retracted state and an extended state in response to an electronic control unit output pinion signal, whereby the starter (24) is capable of selectively engaging an engine (22) for cranking the engine (22). Also, a starter system (20) that facilitates such a method.
B60R 16/02 - Electric or fluid circuits specially adapted for vehicles and not otherwise provided forArrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric
H02J 7/14 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
34.
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.
F02N 11/00 - Starting of engines by means of electric motors
F16H 1/30 - Toothed gearings for conveying rotary motion with gears having orbital motion in which an orbital gear has an axis crossing the main axis of the gearing and has helical teeth or is a worm
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.
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.
H02K 7/02 - Additional mass for increasing inertia, e.g. flywheels
H02K 7/116 - Structural association with clutches, brakes, gears, pulleys or mechanical starters with gears
B60K 6/30 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by chargeable mechanical accumulators, e.g. flywheels
B60K 6/26 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the motors or the generators
A variable flux starter and switch system (222, 222-1) including a starter motor (234) with motor field winding first and second portions (74a, 74b), a control unit (150, 150-1) capable of selectively issuing starter activation and desired flux level signals (68, 70), a motor energizing switch (76) moveable between open and closed positions consequent to issuance of the starter activation signal (68), and a regulating device (84, 84-1 ) that transitions between default and activated operational states consequent to issuance of the flux level signal (70), The regulating device (84, 84-1) has a moveable blocking member (94b) and relatively moveable contact members (86, 88), and in one of the default and activated operational states, electrical contact between the contact members (86, 88) is permitted or prevented by the blocking member (94b). Current through the closed motor energizing switch (76) substantially bypasses a motor field winding portion (74b) when electrical contact between the contact members (86, 88) is permitted, and is conducted through both portions (74a, 74b) when prevented. Also, a method for varying starter motor flux levels.
B60W 30/192 - Mitigating problems related to power-up or power-down of the driveline, e.g. start-up of a cold engine
B60K 6/20 - Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
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.
F16L 37/084 - Couplings of the quick-acting type in which the connection between abutting or axially-overlapping ends is maintained by locking members combined with automatic locking
F16L 37/12 - Couplings of the quick-acting type in which the connection between abutting or axially-overlapping ends is maintained by locking members using hooks, pawls, or other movable or insertable locking members
F16L 5/00 - Devices for use where pipes, cables or protective tubing pass through walls or partitions
39.
SYSTEM, METHOD, AND CIRCUITRY TO RECTIFY AN ALTERNATING CURRENT SIGNAL WITH MOSFET HALF-BRIDGE CIRCUITRY
A system for rectifying an alternating current signal including MOSFET half-bridge circuitry, and magnitude detector circuitry configured to determine whether the peak magnitude of a phase signal is at least equal to a turn-on threshold level and enable the MOSFET half-bridge circuitry to rectify the phase signal in response to the peak magnitude of the phase signal at least equaling the turn-on threshold level. Also, a method for rectifying an alternating current signal including: receiving an alternating current signal from a stator; determining whether the magnitude of the alternating current signal is at least substantially equal to a turn-on threshold level; and, in response to a determination that the magnitude of the alternating current signal is at least equal to the turn-on threshold level, rectifying the alternating current signal to generate a supply voltage.
H02M 7/162 - Conversion of AC power input into DC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a thyratron or thyristor type requiring extinguishing means using semiconductor devices only in a bridge configuration
H02M 7/155 - Conversion of AC power input into DC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a thyratron or thyristor type requiring extinguishing means using semiconductor devices only
H02M 7/02 - Conversion of AC power input into DC power output without possibility of reversal
40.
METHOD AND SYSTEM FOR LOAD DUMP PROTECTION IN AN ELECTRICAL MACHINE
An electric machine (20) including MOSFET half-bridge circuitry (90) configured to receive an alternating current signal (74) from a stator (24) and generate a supply voltage (46) as a function of the alternating current signal (74). The machine (20) includes control circuitry (88) configured to detect whether the supply voltage (46) exceeds a first threshold voltage, and govern the MOSFET half-bridge circuitry (90) to shunt the alternating current signal (74) to a reference voltage (64) based on a detection of the supply voltage (46) exceeding the first threshold voltage. Also, a method for protecting the machine (20) during a load dump event that shunts the alternating current signal (74) to the reference voltage (64) in response to detecting that the supply voltage (46) exceeds the first threshold voltage.
H02H 7/06 - Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for dynamo-electric generatorsEmergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for synchronous capacitors
H02H 7/08 - Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for dynamo-electric motors
An electric machine having a stator and a rotor operably coupled therewith. An accessory is coupled with the electric machine and an electrical device is mounted in a housing. The housing may advantageously include a polymeric shell that is overmolded on a conductive element providing communication between the electrical device and an external circuit. In some embodiments, a printed circuit board is mounted within the housing and thermally coupled with a metallic base member. In other embodiments, a second printed circuit board is provided with the first printed circuit board having a substrate with a greater thermal conductivity than the substrate of the second printed circuit board. The first printed circuit board may include a MOSFET rectifier and may take the form of a ceramic printed circuit board with the second board being an FR-4 board. The electric machine may be advantageously employed as an alternator for a vehicle.
An electric machine (20) including a stator (38), a rotor (46) surrounded by and rotatable relative to the stator (38), a supply terminal assembly (70), and an electronic module (102) electrically connected to the stator (38). The electronic module (102) includes a terminal (162) having at least one bonding region (172). An electrical buss (126) is attached to the supply terminal assembly (70), and includes a first and second conductor portions (146, 148) each having a connection region (160) joined to a bonding region (172) of the terminal (162) of the electronic module (102). The terminal (162) of the electronic module (102) is electrically connected to the supply terminal assembly (70) by the first and second conductor portions (146, 148). Also disclosed is a method for manufacturing such an electric machine (20).
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.
H02P 27/06 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters
B60L 11/18 - using power supplied from primary cells, secondary cells, or fuel cells
B60L 15/20 - Methods, circuits or devices for controlling the propulsion of electrically-propelled vehicles, e.g. their traction-motor speed, to achieve a desired performanceAdaptation of control equipment on electrically-propelled vehicles for remote actuation from a stationary place, from alternative parts of the vehicle or from alternative vehicles of the same vehicle train for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
44.
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.
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
45.
ELECTRIC MACHINE INCLUDING A HOUSING HAVING MATERIALLY INTEGRALLY FORMED COOLANT CHANNELS AND AN OUTER SLEEVE
An electric machine housing includes a housing body having an outer surface provided with a plurality of materially integrally formed ribs defining a plurality of coolant channels. Each of the plurality of materially integrally formed ribs has an outer surface portion. A sleeve is provided on the housing body extending about the outer surface. The sleeve has an inner surface section that is matingly engaged with the outer surface portion of each of the materially integrally formed ribs.
A thermal control system includes a separate cooling system filled with thermally conductive potting compound, in each axial end of a stator. The cooling systems are each thermally mated to the respective end turns of the stator with thermally conductive potting compound and may each have at least one cooling channel that includes a coolant inlet and a coolant outlet. The axial ends may each include an axial end plate having a separate cooling system, where space within the stator end turns and between the end turns and the cooling systems are filled with thermally conductive potting compound.
H02K 1/20 - Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
H02K 3/24 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
H02K 9/197 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator
47.
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.
In accordance with one embodiment, an electronic-dynamic machine is provided and includes a stator assembly having end turns configured to carry current in association with rotation of a rotor, a bladder element including a bladder wall, which is receptive of coolant and which is disposable to contact the end turns such that the coolant is disposable to remove heat from the end turns and a plumbing system configured to pressurize the coolant.
H02K 1/20 - Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
H02K 3/24 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
49.
THERMAL MANAGEMENT OF AN IPM MOTOR WITH CONTAINERIZED FLUID
A rotor of an electric machine includes a rotor core having a plurality of longitudinally extending magnet channels each containing a permanent magnet, and a plurality of moldable containers each containing a heat transfer material and each being contiguous with portions of the respective permanent magnet and its magnet channel. A method of thermal management of an internal permanent magnet (IPM) rotor includes installing, into at least one longitudinally extending magnet channel of a rotor core, a permanent magnet having opposite lateral ends. The method also includes installing a moldable container, enclosing a heat transfer material, into the magnet channel adjacent one of the lateral ends of the permanent magnet. The method further includes transferring heat from the magnet through the container into the rotor core.
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.
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.
An apparatus including a rotating member, a resolver and a mounting structure. The resolver includes a resolver stator and a resolver rotor fixedly mounted on the rotating member via a mounting structure. The mounting structure has a low magnetic relative permeability and isolates the resolver rotor from the rotating member by preventing direct contact between the rotating member and the resolver rotor. The disclosed apparatus may be an electric machine having a rotor fixed to the rotating member and be suitable for use in a hybrid vehicle. The mounting structure advantageously has a relative permeability of no greater than about 2 and may be formed out of stainless steel material. The rotating member may be a rotor hub formed out of steel material having a relative permeability of at least about 50.
G01D 5/20 - Mechanical means for transferring the output of a sensing memberMeans for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for convertingTransducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage by varying inductance, e.g. by a movable armature
G01P 3/42 - Devices characterised by the use of electric or magnetic means
G01B 7/30 - Measuring arrangements characterised by the use of electric or magnetic techniques for measuring angles or tapersMeasuring arrangements characterised by the use of electric or magnetic techniques for testing the alignment of axes
53.
VARIABLE RELUCTANCE RESOLVER HAVING INTEGRAL ELECTROMAGNETIC INTERFERENCE SHIELD AND ROTARY ELECTRIC MACHINE HAVING SAME
A variable reluctance resolver (60, 61 ) including a resolver stator (70) having an annular resolver stator core (88) surrounding an axis (22), a resolver rotor (72) rotatable about the axis (22) relative to the resolver stator (70) and surrounded by the resolver stator core (88), and resolver EMI shielding (112, 114, 126, 128). The resolver EMI shielding (112, 114, 126, 128) includes first (112, 126) and second (114, 128) resolver shields disposed on opposite axial sides of the resolver stator core (88). The resolver shielding (112, 114, 126, 128) has a relative permeability of at least about 50. Also, an electric machine (20, 21 ) having such a variable reluctance resolver (60, 61 ).
H02K 29/08 - Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices using magnetic effect devices, e.g. Hall-plates or magneto-resistors
H02K 11/00 - Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
54.
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.
H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
55.
BUSS BAR ASSEMBLY HAVING ALIGNMENT AND RETENTION FEATURE
A buss bar assembly (70, 70-1, 150) for electrically interconnecting phase leads (42, 214) extending from a plurality of individual coil winding assemblies (34, 34-1, 206, 206-1) of a stator (30, 30-1, 204, 204-1). The buss bar body (72, 72-1, 152) has an annular housing (74, 74-1, 154) defining a central axis (76, 156) and a support (82, 162) for positioning the housing (74, 74-1, 154) relative to the coil winding assemblies (34, 34-1, 206, 206-1). A phase bar (84, 164) disposed about the central axis (76, 156) is at least partially disposed within the housing (74, 74-1, 154) and has contacts (92, 172) at locations (90, 170) about the central axis (76, 156). Each contact (92, 172) is engageable from outside of the annular housing (74, 74-1, 154) and angularly spaced from another contact (92, 172). Also a method for installing a buss bar assembly (70, 70-1, 150).
A method of forming a rotor includes placing a plurality of laminations into a stack having a plurality of longitudinally extending magnet slots, placing a plurality of permanent magnets into ones of the magnet slots, and injecting a low viscosity epoxy resin into the lamination stack, thereby substantially filling the magnet slots with a portion of the epoxy resin having a thermal conductivity greater than 0.3 Watts/(meter * degree Kelvin) and substantially filling axial spaces between adjacent ones of the laminations with a portion of the epoxy resin having a thermal conductivity less than that of the epoxy resin in the magnet spaces.
A stator assembly of an electric machine includes a segmented lamination stack formed of an interconnected series of lamination segment stacks, and a plurality of coil isolators each having a conductor wound thereon, each having a radially outward interlock at each circumferential end thereof, and each having a radially inward interlock at each circumferential end thereof, the coil isolators being serially connected by the interlocks to form a cavity closed down the axial length of the stator assembly, the coil isolators electrically insulating the lamination segments from the conductors.
A buss bar assembly (20) for a multiphase electric machine. The buss bar assembly (20) includes a substantially annular dielectric housing (22) having a central axis (54). A plurality of dielectric mounting members (40) is located within the housing (22). A buss bar plate assembly (28) is disposed in the housing (22), and in engagement with the mounting members (40). The buss bar plate assembly (28) includes a substantially planar dielectric substrate (30) that has opposing, substantially planar axial sides, and substantially surrounds the central axis (54). The buss bar plate assembly (28) also includes a plurality of electrically conductive phase bars (32A, 32B, 32C) applied to at least one of the opposing substrate sides. Each phase bar (32A, 32B, 32C) is for electrical connection to a different one of multiple electrical phases and substantially surrounds the central axis (54), with the phase bars (32A, 32B, 32C) being electrically isolated from each other within the housing (22).
An electric machine having a segmented core wherein the core includes a plurality of core segments. The segments are secured together with a belt member that substantially encircles the core segments but does not extend the full axial length of the segments. In some embodiments, the individual segments include a recess on their outer radial surface in which the belt member is positioned. A method of assembling an electric machine having a segmented core is also disclosed. Coils are wound about the poles of a plurality of segments. After forming the coils on the segments, the segments are joined together with a belt member wherein the belt member does not extend the full axial length of the core segments and is positioned between the two axial ends of the core assembly.
A stator assembly includes a coil isolator having a first flange, a phase separator, and a living hinge connecting the first flange and the phase separator, the coil isolator structured for enclosing a stator lamination stack and for winding a coil thereon in electrical isolation from the stack, the phase separator being radially closeable for enclosing a portion of the coil within the coil isolator. A method of forming a stator includes placing an isolator onto a lamination stack segment, winding a coil onto the isolator, folding a phase separator of the isolator to enclose a portion of the coil, and placing a plurality of bus bars onto the phase separator in physical partition from one another. A method of insulating a phase bus from a stator coil includes forming a coil insulator having a bobbin, a phase separator, and a living hinge coupling the bobbin to the phase separator.
A buss bar assembly (20) for a multiphase electrical machine, including a substantially annular dielectric housing (22) having a central axis (54), a plurality of dielectric phase bar mounting members (40) located within the housing (22), and a plurality of electrically conductive phase bars (28). The phase bars (28) are disposed in the housing (22) and substantially surround the central axis (54). Each phase bar (28) has opposing, substantially planar axial sides and is in engagement with at least one phase bar mounting member (40). An axial side of each phase bar (28) is in superposition with an axial side of another phase bar (28) whereby the plurality of phase bars (28) are axially stacked along the central axis (54). The phase bars (28) have mutually spaced positions relative to each other in directions along the central axis (54), these positions defined by the phase bar mounting members (40) whereby the phase bars (28) are electrically isolated from each other within the housing (22).
An electric machine including a housing having a body including an inner surface that defines an interior, a first end defining an opening exposing the interior, and a second end. A stator is fixedly mounted to the inner surface of the housing. A rotor is supported within the interior. The rotor defines an axis of rotation. An end cover extends across the opening adjacent one of the first end and the second end of the stator. A cooling system is carried by the end cover. The cooling system includes a body having a cooling fluid plenum, a plurality of stator nozzles and a plurality of rotor nozzles. The stator nozzles are configured and disposed to direct multiple jets of a coolant toward the stator and the plurality of rotor nozzles are configured and disposed to guide multiple jets of the coolant toward the rotor.
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.
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.
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.
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
H02P 29/00 - Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
66.
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.
H02K 3/28 - Layout of windings or of connections between windings
H02P 1/26 - Arrangements for starting electric motors or dynamo-electric converters for starting dynamo-electric motors or dynamo-electric converters for starting an individual polyphase induction motor
An access port cover system, including a housing for an item, the housing defining interior and exterior regions and including an access port through which access to the item from the exterior region is provided, a cover inhibiting access through the access port from the exterior region to the interior region, and a fastener connectable to the housing and the cover. The fastener has an actuation portion for disconnecting the housing and the cover to permit access through the access port from the exterior region to the interior region, the actuation portion being inaccessible from the exterior region when the fastener is connected to the housing and the cover.
B60R 16/02 - Electric or fluid circuits specially adapted for vehicles and not otherwise provided forArrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric
B60R 16/00 - Electric or fluid circuits specially adapted for vehicles and not otherwise provided forArrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
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.
H02P 9/08 - Control of generator circuit during starting or stopping of driving means, e.g. for initiating excitation
H02P 9/04 - Control effected upon non-electric prime mover and dependent upon electric output value of the generator
H02J 7/14 - Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
Embodiments of the invention provide an electric machine module including a stator assembly. The stator assembly includes a stator core comprising a plurality of slots. Conductors can be at least partially disposed within the slots. The conductors can include leg portions and can be positioned so that at least some of the slots include a first leg portion, a second leg portion, a third leg portion, and a fourth leg portion. The stator assembly can include first clearance apertures defined by between circumferentially adjacent first leg portions, second clearance apertures that can be defined between circumferentially adjacent second leg portions, third clearance apertures that can be defined between circumferentially adjacent third leg portions, and fourth clearance apertures that can be defined between circumferentially adjacent fourth leg portions. In some embodiments, the second and third clearance apertures can comprise a greater circumferential size relative to the first and fourth clearance apertures.
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.
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.
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.
H02K 9/193 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil with provision for replenishing the cooling mediumArrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil with means for preventing leakage of the cooling medium
H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
73.
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.
An electric machine and vehicular subsystem, apparatus includes a connection disposed within a housing and connecting a high voltage line with the electric machine. A controller controls the coupling of a power source to the high voltage line. A reed switch is positioned within the housing proximate the high voltage line connection. A member is removably mounted on the housing and structured so that removal of the member is necessary to gain access to the high voltage line connection, the member having a magnet. At least one low voltage communication line extends from the reed switch to the controller. Removal of the member from the housing opens the reed switch. Mounting of the member to the housing closes the reed switch. The controller terminates the providing of electric power to the high voltage line when the member is removed from the housing.
An electric power source supplies electrical power to an electric machine of a vehicle via a plurality of high voltage lines. A plurality of connections are disposed within a housing for connecting the high voltage lines. A cover member encloses a hidden magnet and is removably secured to the housing so that removal is necessary to obtain access to the high voltage lines. A reed switch is mounted proximate the cover member, when secured, within a magnetic field of the magnet, whereby the reed switch is closed when the cover member is secured and is open when the cover member is removed. A controller is controllably coupled to the power source via a control connector and circuit of the electric machine. Such circuit extends from the reed switch to the controller, where the controller causes the electric power source to stop supplying electrical power when the cover member is removed.
H02H 5/00 - Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal non-electric working conditions with or without subsequent reconnection
H02H 5/12 - Emergency protective circuit arrangements for automatic disconnection directly responsive to an undesired change from normal non-electric working conditions with or without subsequent reconnection responsive to undesired approach to, or touching of, live parts by living beings
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.
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.
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.
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.
H01B 7/17 - Protection against damage caused by external factors, e.g. sheaths or armouring
H01B 3/38 - Insulators or insulating bodies characterised by the insulating materialsSelection of materials for their insulating or dielectric properties mainly consisting of organic substances plasticsInsulators or insulating bodies characterised by the insulating materialsSelection of materials for their insulating or dielectric properties mainly consisting of organic substances resinsInsulators or insulating bodies characterised by the insulating materialsSelection of materials for their insulating or dielectric properties mainly consisting of organic substances waxes condensation products of aldehydes with amines or amides
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. In some embodiments, a plurality of coolant apertures can be disposed through at least a portion of the housing. A stator assembly can be at least partially disposed within the housing and can include a plurality of coolant channels being in fluid communication with the machine cavity. Each of the coolant channels includes at least one radial subunit and at least one axial subunit. The radial subunits are fluidly coupled to some of the coolant apertures so that the coolant jacket is in fluid communication with the machine cavity via the coolant channels.
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.
A high- voltage electric machine has one or more terminals at which wires are to be electrically connected to the machine. The machine's housing includes a cable entrance leading to the terminal(s) through which the wire is inserted. Access holes through the housing enable a technician to reach the terminals (for example, with a tool, such as a screwdriver) to connect each wire to a terminal. In some embodiments, the direction of the access through the hole to the terminal is substantially perpendicular to the direction from which the wire reaches the terminal. A plug may be inserted into each access hole to prevent accidental contact with the terminal(s), such as screw-type or friction-fit plugs.
H02K 13/00 - Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windingsDisposition of current collectors in motors or generatorsArrangements for improving commutation
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.
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.
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.
H02K 3/28 - Layout of windings or of connections between windings
H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
86.
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.
An electric machine with a stator and a rotor. The rotor core is formed by a stack of laminations with the laminations being generally planar and oriented substantially perpendicular to the rotational axis. One of the laminations includes an axially projecting tab. An electrically conductive end ring is located at an axial end of the rotor core and is in communication with a plurality of axially extending conductor bars on the rotor core. The tab is coupled with the end ring and resists a portion of the centrifugal forces acting on the end ring during rotation of the rotor. A plurality of such tabs may be used to provide support to the end ring. A method of manufacture is also disclosed.
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.
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.
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
90.
ELECTRIC MACHINE INCLUDING A SWITCH TERMINAL AND METHOD OF CONNECTING AN END PORTION OF A WIRE TO A TERMINAL OF AN ELECTRIC MACHINE
An electric machine includes a wire conductor having at least one end, a terminal configured to be operatively connected to the at least one end of the wire conductor, and a terminal member having a first end section configured and disposed to establish a mechanical bond and an electrical connection with the at least one end of the wire conductor, and a second end section configured and disposed to establish a mechanical link and an electrical connection with the terminal.
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.
H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
An electric machine having a rotor with an axially extending magnet slot. A magnetic material is mounted in a magnet holder to form a magnet holder assembly which is installed in the magnet slot of the rotor. In some embodiments, the magnet holder assembly substantially fills the entire slot volume. In other embodiments, the magnet holder assembly defines a greater thickness of dielectric material between the magnetic material and the major side of the slot nearest the stator than between the magnetic material and the opposite side of the slot. In still other embodiments, a plurality of axially abutting magnet holder assemblies are installed in the magnet slot. In yet other embodiments, the magnet holder comprises two materials with different durometer values wherein one of the materials is resiliently, compressibly engaged with the slot to secure the magnet holder assembly therein. A method of manufacture is also disclosed.
A method of joining a plurality of electrical conductors in an electric machine. The method comprises the steps of providing a core and positioning the plurality of conductors within the core in concentric rings. The conductors include ends extending from the core. The method further comprises the steps of holding together at least two adjacent ends of the conductors, joining the adjacent ends to form a joint, and forming the joint to include at least a substantially planar portion. The method further comprises the step of releasing the adjacent ends of the conductors.
An apparatus for and a method of brazing copper armature conductors to a commutator during the production of automotive starting motors. In the inventive method, two conductors of the armature are brazed together and are also brazed to the corresponding slot in a commutator in a single step. The process is aided by an inventive brazing clip which includes a cleat or inwardly bent tab that engages the conductor of an armature to hold it in place.
H02K 1/28 - Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
H02K 13/00 - Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windingsDisposition of current collectors in motors or generatorsArrangements for improving commutation
95.
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.
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.
F02N 15/02 - Gearing between starting-engines and started enginesEngagement or disengagement thereof
F16D 41/064 - Freewheels or freewheel clutches with intermediate wedging coupling members between an inner and an outer surface the intermediate members wedging by rolling and having a circular cross-section, e.g. balls
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.
H02K 15/10 - Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes
H02K 3/34 - Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation
H01B 13/08 - Insulating conductors or cables by winding
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. In some embodiments, a plurality of coolant apertures can be disposed through at least a portion of the housing to fluidly connect the coolant jacket and the machine cavity. The coolant apertures can comprise a first group configured and arranged to direct a first volume from the coolant jacket. The coolant apertures can comprise a second group configured and arranged to direct a second volume from the coolant jacket. In some embodiments, the first volume can be greater than the second volume.
Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, an electric machine can be positioned within the machine cavity. In some embodiments, the electric machine can include a stator assembly including potted stator end turns. An end turn member can be positioned within the machine cavity and can include a radially inward flange and a radially outward flange axially extending from a central region. The end turn member is configured and arranged so that the flanges are substantially adjacent the stator end turns. The end turn member can include at least one second member aperture disposed through a portion of the central region.
Embodiments of the invention provide an electric machine module including an electric machine. The electric machine includes a rotor and a stator assembly. The machine includes 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 comprise 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. The pump may be internal to the machine, mounted at an interface between the inside and outside of the machine, or alternatively, it may be externally mounted.
patents
