Borgwarner Inc.

Remy Technologies, LLC

Jiwon Chung

Kirk E Neet

Rectangular conductor wires are often used in alternator applications requiring a high slot fill to maximize output and efficiency. However for lower output and efficiency applications, round conductor wire may increase cost competiveness in these alternators. A common lamination for a core alternatively accommodates both rectangular conductor wires and round conductor wires for different applications without any other component changes. The lamina has a slot that aligns round wire in a single row within the slot and provides a predetermined clearance from the slot opening. A stator core formed from these laminae has a relatively high slot fill factor when wound with the round wire. The same stator core can be alternatively wound with square wire to increase the slot fill factor even higher. The common lamination results in two stator configurations: a high slot fill version (round wire) and a very high slot fill version (square wire).

Common lamination component for accommodating multiple conductor geometries in an electric machine

An integrated magnetic switch assembly includes a winding assembly portion having a housing, and a cover assembly mounted to the housing. The cover assembly includes at least one rivet terminal and at least one power terminal The at least one rivet terminal includes a body that extends through the cover assembly. The body has a first end that extends to a second end, and an opening that includes a first diameter that extends from the first end to the second end. A sealing member is positioned at the first end of the body about the opening of the at least one rivet terminal. The sealing member includes an opening having a second diameter that is smaller than the first diameter. A sealing element is positioned between the at least one power terminal and the cover assembly.

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Fishers, IN, United States of America

Jiwon Chung