Visteon Global Technolgoies, Inc.

Ford Motor Company Limited

F;visteon Global Technologies, Inc.

Hanyang Ben Chen

Kirk E Neet

Michael Timothy York

Steven John Yockey

Eric David Bramson

Mark J Pillote

Steven S Yockey

A stator for an electric machine includes a generally cylindrically-shaped stator core having a plurality of core teeth that define a plurality of core slots, the core slots extend between first and second ends of the stator core. A stator winding has a plurality of phases, N, each phase including at least one conductor having a plurality of slot segments housed in the core slots, the slot segments are alternately connected at the first and second ends by a plurality of end loop segments. At least one conductor has a slot segment that is switched with an adjacent conductor such that the conductor has an end loop segment having a pitch equal to N+1 and the end loop segment of the adjacent conductor has a pitch equal to N&#x2212;1, wherein the end loop segments of the conductor and the adjacent conductor do not cross one another. The stator also reduces overall noise of an electric machine.

Low noise stator winding having a phase angle shift

A system, for determining a starting position angle of an electric motor, includes a plurality of windings, a circuit, a processor, and at least one voltage sensor. The circuit is configured to create a pulse current field in at least one of the plurality of windings. The sensor is configured to sense a pulse current field response in a corresponding winding of the plurality of windings. The processor is in communication with the voltage sensor and is configured to determine the position angle of the rotor based on the pulse field response.

Electric machine with actively controlled switches

A switching circuit for an electric machine is provided. The switching circuit includes switches for energizing the phase windings of the machine and sensors for driving the state of the switches. The switches are voltage-controlled devices and the sensors are coils.

Alternator rectifier with coil-sensor controlled MOSFETs

A stator for an electric machine includes a generally cylindrically-shaped stator core having a plurality of circumferentially spaced core slots. A stator winding includes a plurality of phases, each including at least a first filar and a second filar extending circumferentially around the stator core to form a plurality of layers. Each of the filars is a conductor having a plurality of slot segments disposed in the core slots. The slot segments are alternately connected at the first and second ends of the stator core by a plurality of end loop segments that may form a cascaded winding pattern. The plurality of filars of each phase alternating radial positions with one another within at least one end loop segment at discreet locations around the stator core such that the average radial position of the slot segments of the first filar conductors is substantially equal to that of the second filar.

Stator winding having transitions

An alternator for a motor vehicle includes a current generation device and a rectifier. The current generation device has multiple phase stator windings in which AC currents are generated. The rectifier is connected to the windings of the current generation device. The rectifier includes multiple sets of first and second diodes for the multiple phase windings. At least one of the first and second diodes of each set is a Schottky diode. A voltage clamping device is connected to the rectifier to protect the Schottky diodes from surge reverse voltage.

Alternator rectifier

A stator for an electric machine includes a stator core having a plurality of circumferentially-spaced and axially-extending core slots. The core slots extend between a first and a second end of the stator core and a stator winding having a plurality of phases is positioned therein. Each of the phases includes a first pair of conductors connected in parallel and a second pair of conductors connected in parallel, in turn connected to one another in series to define a single phase of the stator winding. The first pair of conductors and the second pair of conductors occupy adjacent slots such that each single phase of the stator winding occupies two adjacent slots within the stator core. Each conductor has a plurality of slot segments housed in the core slots that are alternately connected at the ends of the stator core by a plurality of end loop segments.

Vehicle alternator stator winding having dual slot configuration

An electric machine for a motor vehicle is provided, the electric machine generally comprising a claw-pole rotor and a stator circumscribing the rotor. Adjacent pole fingers of the rotor define a distance P representing the axial distance between the magnetic centers of the adjacent pole fingers. The stator generally includes a stator core defining a distance H representing the axial height of the lamination stack. Preferably, the electric machine has a ratio of P to H (P/H) in the range of 0.29 to 0.45, resulting in an improvement in the power output of the electric machine.

Alternator having claw-pole rotor

A stator for an electric machine includes a generally cylindrically-shaped stator core having a plurality of circumferentially spaced core slots. A stator winding includes a plurality of phases, each including a plurality of filars, each filar extending circumferentially around the stator core to form a plurality of layers. Each of the filars is a conductor having a plurality of substantially straight segments disposed in the core slots. The straight segments are alternately connected at the first and second ends of the stator core by a plurality of end loop segments. The filars of a particular phase each have an average radial position within the stator core, and are staggered throughout the layers such that a distance between the average radial position of each filar and the average radial position of the other filars is minimized.

Electrical machine having a stator winding with a plurality of filars

A stator assembly for an alternator in accordance with the present invention includes a generally cylindrically-shaped stator core having a plurality of core slots formed along the inner surface thereof and defined by a radial depth and wherein a stator coil is disposed. The core slots thereby define a plurality of teeth therebetween, which are connected to the stator core by a yoke portion. The core slots are shaped and extend between a first and a second end of the stator core. A plurality of clips closely fit into one of said core slots for lining each respective core slot. The clips have a pair of extending leg members connected to a back end and forming an aperture therebetween. The clips are formed from a magnetically permeable material. A stator winding includes substantially straight wire segments that are received by the clips formed of substantially straight wire segments. The substantially straight wire segments of the stator winding and the clips are electrically insulated from one another. At least one of the extending leg members is bent towards the other leg member over a portion of the at least one row of substantially straight wire segments in the clips, narrowing the aperture between the extending leg members. Each of the plurality of clips and said substantially straight wire segments are each inserted into one of the plurality of core slots. Slits are added in these clips to reduce eddy current loss.

Process for assembling an alternator stator with clips that allows radial insertion of square wire with small slot openings

An alternator of the present invention includes a housing, a stator assembly mounted stationary within the housing, and a rotor assembly mounted rotatably within the housing in functional engagement with the stator assembly. An air gap extends annularly around the alternator between the rotor assembly and the stator assembly. The rotor assembly has a first end and a second end, and the air gap has a non-uniform thickness that varies along the axial length of the rotor assembly between the first and second ends of the rotor assembly. This non-uniform thickness is designed to avoid interference between rotor outer surface and stator inner surface at high rotor spin speed, but minimize the averaged air gap thickness for high alternator performance.

Claw-pole alternator with non-uniform air gap

A rotor assembly for an alternator having a rotor shaft, a field coil wound on an insulative bobbin, and pair of poles mounted on the shaft around the field coil and bobbin. Each of the poles includes a pole core and a plurality of pole fingers. The plurality of pole fingers each have an inner surface facing the field coil. The plurality of pole fingers and their inner surface is structured to increase the electric output power if the alternator while decreasing the weight and volume of the alternator, thereby increasing the alternator maximum speed and reducing the deflection of the pole fingers.

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Ypsilanti, MI, United States of America

Hanyang Ben Chen