Remy Technologies, LLC

Borgwarner Inc.

Delco Remy America, Inc.

Remy Inc.

Cummins Inc.

Remy International, Inc.

David A Fulton

Kirk E Neet

Bradley Duane Chamberlin

Wei Cai

Joshua B Lahrman

Andrew Dragon

Ralph H Johnston

Matthew R Conner

William Cai

Christopher Congdon

James D Stuber

Larry A Kubes

James J Ramey

Joel Michael Gray

Ross A Gresley

David R Crecelius

James A Spellman

Arlen Phillip Suter

Jeffrey L Mummert

German Holguin Pallares

Peter K Farrar

Darrell Stephens

Timothy C Monnier

Pawel Tetela

George Pelton

Gabriel Domingues

Jim Shaw

A stator for an electric machine includes a core and a multi-phase winding arrangement positioned on the core. Each phase of the winding arrangement includes a plurality of parallel paths defining a plurality of poles for the electric machine. Each parallel path includes a plurality of coils positioned on the core, each coil defined by coil legs and end turns. The coil legs include left legs and right legs extending through the slots of the core. The left legs and right legs of each coil are connected by first end turns at one end of the core and second end turns at an opposite end of the core. Each pole of the electric machine is associated with a pole slot set comprised of multiple slots on the stator core. For each pole slot set, legs for each parallel path extend through one of the slots of said pole slot set.

Diamond coil stator with parallel paths and balanced winding arrangement

A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).

Stator with printed end turns and methods of making the same

A rotor includes a shaft having an outer surface including a first diameter and a flange extending from the outer surface. A first plurality of laminations is arranged about the shaft. The first plurality of laminations includes an outer annular surface and an inner surface defining an opening including a second diameter that is substantially equal to the first diameter. A second plurality of laminations is arranged about the shaft and coupled to the first plurality of laminations. The second plurality of laminations include an outer annular surface portion and an inner surface portion defining a third diameter that is greater than the first diameter.

Rotor for an electric machine

A starter motor controller for a starter motor operatively connected to a single coil solenoid includes a first pair of switches including a first solenoid switch and a second solenoid switch. The first solenoid switch selectively completes a first electrical circuit for delivering a first electrical current to the single coil solenoid and the second solenoid switch selectively completes a second electrical circuit for delivering a second electrical current to the single coil solenoid that is less than the first electrical current. A second pair of switches includes a first starter motor switch and a second starter motor switch. The first starter motor switch selectively completes a first electrical circuit for delivering a first electrical power to the starter motor and the second starter motor switch selectively completes a second electrical circuit for delivering a second electrical power to the starter motor that is greater than the first electrical power.

Starter controller for starter motor

An electric machine configured to increase resistance between a brush and a commutator of the electric machine at a wear condition of the brush consistent with end of service life.

Brush wear indicator

A starter assembly is provided and includes a shaft to transmit rotation to a ring gear via a pinion and including a first helical spline with angling directed reversely with respect to a direction of the rotation and an elastic element anchored on the first helical spline to bias the pinion in an axial direction. The ring gear and the pinion include complementary teeth and the pinion defines a bore with a second helical spline to register with the first helical spline such that the pinion teeth are forwardly rotated into ring gear teeth engagement positions as the shaft moves axially relative to the pinion in the axial direction.

Starter assembly

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.

Resolver with mounting structure and method

An electric machine includes a pair of substantially aligned sheet metal housing sections each including a substantially 'L' shaped portion, at least one cooling channel being formed at an axial end between the two sections, and a plurality of power electronics components engaged with at least one of the housing sections adjacent the axial end cooling channel. An embodiment includes a stator, a pair of housing sections enclosing the stator, power electronics components positioned at an axial end of the electric machine for controlling operation of the electric machine, and a coolant flow path that includes a power electronics cooling channel formed at the axial end between the housing sections. A method includes forming an axial end cooling channel between two sheet metal housing sections, and positioning power electronics components at the axial end along the cooling channel, whereby heat from the electronics components is transferred to the cooling channel.

L-shaped sheet metal cooling jacket with baffles and integrated power electronics

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.

Starter system

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.

Starter with speed sensor assembly

Embodiments of the invention provide a starter machine control system including an electronic control unit. The control system can include a starter machine that is in communication with the electronic control unit. The starter machine can comprise a solenoid assembly that includes at least one biasing members and a coil winding. The starter machine can also include a motor that is coupled to a pinion. The motor can include a field assembly and an armature assembly. The field assembly can include a support body and permanent magnets that are supported within the support body. A plurality of flux members can be disposed between the permanent magnets. A plurality of windings can be disposed around the flux members and can be coupled to a control circuit.

Starter machine system and method

A variable flux starter and switch system including a starter motor with motor field winding first and second portions, a control unit capable of selectively issuing starter activation and desired flux level signals, a motor energizing switch moveable between open and closed positions consequent to issuance of the starter activation signal, and a regulating device that transitions between default and activated operational states consequent to issuance of the flux level signal. The regulating device has a moveable blocking member and relatively moveable contact members, and in one of the default and activated operational states, electrical contact between the contact members is permitted or prevented by the blocking member. Current through the closed motor energizing switch substantially bypasses a motor field winding portion when electrical contact between the contact members is permitted, and is conducted through both portions when prevented. Also, a method for varying starter motor flux levels.

Variable flux starter and switch system

Embodiments of the invention provide a starter machine including a housing. A motor can be positioned within the housing and coupled to a gear train, which can be coupled to a shaft. A switched reluctance solenoid assembly can be positioned within the housing and capable of being coupled to inverters that communicate with an electronic control unit. The switched reluctance solenoid assembly includes at least two switched reluctance stator assemblies and a rotor that is coupled to the shaft. The rotor can also include an integral pinion and is movably positioned within the switched reluctance stator assemblies. The rotor is capable of linear and rotational movement.

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.

Growing community of inventors

Anderson, IN, United States of America

David A Fulton