Gm Global Technolgoy Operations, Inc.

John Stilianos Agapiou

Thomas Arthur Perry

James Gregory Schroth

Hongliang Wang

Michael D Hanna

John Patrick Spicer

Ronald Michael Lesperance

Richard Murray Kleber

Jie Gu

Sunil Nandwani

Qigui Wang

Gary Lee Jones

Yhu-Tin Lin

Pulak Bandyopadhyay

Liang Wang

Sean R Wagner

John D Campbell

Chi-Hung Shen

Yew Sum Leong

Sheri K Kurgin

Paula J Deeds

Phillip A Bojda

Jae Min Lee

Daniel L Simon

Michael E Swanger

Ranajit Ghosh

Lei Hao

Blair E Carlson

Jian Yao

Edward L Kaiser

Andrew Leslie Bartos

Michael P Balogh

Huaxin Li

Jeffrey A Abell

Daniel J Wilson

John C Morgante

Arthur L McGrew, Jr

Martin Stephen Kramer

Dmitriy Bruder

Mark A Kramarczyk

Pei-Chung Wang

Song He

SeungHwan Keum

Alexander Millerman

Wuhua Yang

Frederick W Rhoads

Fangming Gu

Zhen Gao

Steven L Burkholder

Craig Raymond Brooks

John Alverio

Paul J Boone

Stephen R Smith

Jeffrey Morgan Alden

Edward Panozzo

Eric A Steinhilper

Christopher B Preston

Teresa U Holiness-Stalling

Patrick M Hilber

Dalton D Matznick

Christine Anne Blake

Daniel K Owusu

Ante Tony Lausic

Paul W Tanis

Mark A Smith

Edwin H Chang

Jon Matthew Radlick

Wayne Szostak

Thomas E Berry

Robert B Trent

Michael J Owen

Lee B Moonen

Michael Herold

Narasimha Kramadhati

Phillip K Steinacker

Robert J Hogarth

Robert K Aas

Aloysius Anagonye

James A Bucan

A rotatable stator sensor device includes a stator support plate configured to support a steel stator having multiple teeth, a rotary table electrically isolated from the stator support plate, and at least two sensors on the rotary table. The at least two sensors are located within an inner circumference of the steel stator, each of the at least two sensors including two sensor legs, and a distance between the two sensor legs corresponds to a distance between two of the multiple teeth of the steel stator. The device includes a sensor rotation control module configured to rotate the at least two sensors between a first position aligned with a first set of the multiple teeth of the steel stator, and a second position aligned with a second set of the multiple teeth of the steel stator.

Rotatable stator sensor device

A testing system includes an AC signal generator configured to selectively generate a sinusoidal signal including a plurality of cycles. A dielectric strength and partial discharge tester sequentially performs dielectric strength and partial discharge testing of a stator of an electric machine using the sinusoidal signal. Another testing system includes an impulse signal generator configured to selectively generate an impulse signal including a plurality of cycles. A surge and partial discharge tester for sequentially performing surge and partial discharge testing of a stator of an electric machine using the impulse signal.

Systems and methods for testing partial discharge during the leakage and/or surge tests for electric machines

An axial flux electric motor includes a housing including an inner surface and a stator fixedly mounted in the housing. The stator includes a plurality of stator segments each supporting a winding, an inner support member defining a central passage, and an outer annular member constraining the plurality of stator segments. The outer annular member includes an outer surface portion abutting the inner surface of the housing. A thermal connection system is disposed between the outer surface portion of the outer annular member and the inner surface. The thermal connection system transfers heat from the stator into the housing.

Thermal connection system for a stator core of an axial flux electric motor

An induction rotor assembly having conductive bars is provided. The assembly comprises a lamination stack comprising a body having a first end and second ends to define a longitudinal axis. The body has an outer circumferential portion extending from the first end to the second end. The outer portion has a plurality of walls defining open slots formed from the first end through the second end. The assembly further comprises a first ring disposed on the first end and a second ring disposed on the second end. The assembly further comprises a plurality of conductive bars extending between the first and second rings. Each conductive bar is disposed in one of the slots such that the respective conductive bar is in contact with the lamination stack and connects the first and second rings. Each bar comprises an inner portion and a conductive outer skin disposed about the inner portion.

System and method of making a cast induction rotor assembly having conductive bars

An interlocking tool for a for forming stator end turns includes a first member including a first base having a first surface. A first ring extends from the first surface and a second ring extends from the first surface radially outwardly of the first ring. The second ring is spaced from the first ring by a first gap. A second member includes a second base having a first surface portion. A first ring element extends from the first surface portion and a second ring element extends from the first surface portion radially inwardly of the first ring element. The second ring element is spaced from the first ring element by a second gap. The second ring is positioned in the second gap, and the second ring element is positioned in the first gap. The first member is rotatable relative to the second member.

Interlocking tool for forming stator winding end turns

A system for inspecting a stator stack includes a rotary table, an imaging device configured to take a plurality of images of a portion of the stator stack including a stator slot, an illuminator configured to apply illumination through the stator slot, and an alignment and monitoring system configured to monitor and orient the stator slot relative to the imaging axis. The alignment and monitoring system includes a tilting system configured to move the stator slot between a plurality of orientations relative to an imaging axis, the imaging device configured to take a respective image at each of the plurality of orientations, a controller configured to control the tilting system based on one or more measurements of each image, and a processor configured to analyze each image and select an orientation of the stator slot as an optimal orientation for inspection of the stator slot.

Optical inspection of stator slots

A casting die includes a first ingate defining a first annular chamber and a second ingate defining a second annular chamber and spaced from the first ingate. The die includes a first end ring gate concentric with the first ingate and defining a first end ring chamber in fluid communication with the first annular chamber, and a second end ring gate concentric with the second ingate and defining a second end ring chamber in fluid communication with the second annular chamber. The die includes runners interconnecting the first and second end ring gates. Each of the runners defines a conductor bar channel in fluid communication with the first and second end ring chambers. The die includes an overflow gate disposed between the first and second ingates, wherein the overflow gate defines an annular overflow chamber in fluid communication with the conductor.

Casting die and method of mitigating entrained air in a cast article

A method of inspecting a stator stack includes disposing the stator stack on a support surface of an inspection system, and performing a depth measurement of a stator slot. The depth measurement includes rotating the stator slot along a first direction to a plurality of first orientations, taking a first image at each of the first orientations, and measuring a depth based on at least one of the first images. The method includes performing a width measurement of the stator slot, which includes rotating the stator slot along a second direction to a plurality of second orientations, taking a second image at each of the second orientations, and measuring a width based on at least one of the second images. The method further includes inspecting edges of the stator slot in the at least one of the first images to detect a potential deviation.

Methods and systems for detecting partial discharge in a stator for an electric motor are provided. An exemplary method includes applying a high voltage AC sinewave input signal to the stator and energizing at least one winding therein. The method includes sensing a first resulting load signal occurring in the stator with a first device and filtering the first resulting load signal to form a first high frequency signal indicating any partial discharge (PD) voltage occurring in the stator. The method also includes sensing a second resulting load signal occurring in the stator with a second device and filtering the second resulting load signal to form a second high frequency signal indicating any partial discharge voltage occurring in the stator. Further, the method includes processing the first and second high frequency signals to form a processed signal indicating whether partial discharge occurred.

Detection of partial discharge

An induction motor includes a stator and a rotor. The stator is configured to generate a rotating magnetic field. The rotor is disposed inside the stator, separated from the stator by an air gap, and is configured to rotate around an axis in response to the rotating magnetic field. The rotor includes a rotor core, multiple end rings, and multiple collars. The end rings are attached at opposite ends of the rotor core. Each end ring has one of multiple regions disposed outside the air gap. Each region has an outer surface. The collars are attached in a prestressed condition around the outer surface of each region. The prestressed condition is configured to maintain a compressive stress in the end rings at a maximum-designed rotational speed of the rotor.

Induction motor with collar-reinforced end rings

Stator cores and methods for fabricating stator cores are provided. An exemplary stator core includes a stack of laminations. Each lamination in the stack of laminations comprises a yoke and a plurality of tooth segments fixed to the yoke.

Segmented stator laminations

An electric machine may include a substantially annular stator stack having a plurality of laminations which include mounting ears. A fraction of the laminations may be oriented such that the mounting ears are angularly offset from the others. The stator may be secured to a housing at both mounting ear locations thus improving structural rigidity and enhancing performance.

Electric machine and method for manufacture

Systems and methods are provided for fixturing hairpins for joining by welding. A fixture system includes an outer structural ring fixed relative to an inner structural ring and mates with the component around its hairpin type conductor ends. Dielectric rings are disposed between conductor pairs. Clamp rings are disposed on opposite sides of the dielectric rings. One clamp ring and one dielectric ring define an opening receiving one conductor pair. Another clamp ring and another dielectric ring define another receiving another conductor pair. The clamp rings are movable toward one another to align and crowd the conductor pairs between the clamp rings and the dielectric rings prior to welding.

Stator welding fixture system and method

A partial discharge calibration standard apparatus may include a first and second rigid members defining respective first and second facing surfaces. An electrically insulating material may be disposed between the facing surfaces. The apparatus may further include a pressure member maintaining the rigid members together, thereby fixing the first and second facing surfaces in a substantially parallel spaced relation across the insulating material such that a partial discharge threshold magnitude for an electrical potential difference between the first and second facing surfaces is determined. The insulating material may prevent a partial discharge of an electrical potential from the first facing surface to the second facing surface below the partial discharge threshold magnitude, while allowing the electrical potential difference to be discharged from the first facing surface to the second facing surface through the insulating material when the electrical potential difference is increased to the partial discharge threshold magnitude.

Calibration standard for partial discharge measurement

A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Modular stator

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Rochester Hills, MI, United States of America

John Stilianos Agapiou