Gm Global Technolgoy Operations, Inc.

Borgwarner Inc.

Timothy J Alfermann

Ahmed Mostafa El-Antably

Arthur L McGrew, Jr

Arthur L Mc Grew, Jr

Charles B Lucas

Alan G Holmes

Edward L Kaiser

Brian J Gallert

Mark L Anderson

Ryan Van Tiem

Tim Sailors

Daniel E Wilkins

Drake J Sayre

Mariusz J Kalisz

Timothy J Sailors, Jr

Brian Maskew

Mingze Yang

A stator assembly of an electric machine includes of stator leads extending outward from one end of the stator core. A busbar assembly includes a busbar body supporting a plurality of lead connectors that are connected to corresponding stator leads. An alignment plate is interposed between the stator assembly and the busbar assembly. The alignment plate includes a rigid base plate having a planar bottom face supported on the top surface of the end turns and an opposite top face supporting the busbar body. The base plate defines a plurality of openings corresponding to the plurality of stator leads and arranged to be aligned with the stator leads. One or more of the stator leads extends through a corresponding one of the plurality of openings. Each of the openings is sized and configured for a close running fit with the stator lead or leads extending therethrough.

Busbar base plate

A radially insertable thermistor assembly for installation into a stator having a plurality of stator windings. The radially insertable thermistor assembly includes a thermistor housing having one or more radially outwardly extending elements that extend through a void between two adjacent stator windings and being operable to connect to one of the stator and the plurality of stator windings, and a sensing element arranged at the thermistor housing.

System of radially inserting a thermistor into a stator core

An alternator for generating electrical power to one or more components of a power network includes a machine portion including a stator, a rotor and a rectifier, a battery connection terminal connected to the machine portion and configured to be connected to a battery, and an isolation device integral to the alternator. The isolation device is located on an electrical path between at least the machine portion and the battery connection terminal, and the isolation device is configured to isolate at least one of the alternator and another component of the power network from receiving electric current from the battery based on an undesirable condition occurring in the power network.

Electrical isolation of an alternator

An alternator system includes an alternator including a housing, a stator having a stator assembly fixedly mounted relative to the housing, and a rotor rotatably mounted relative to the housing. The stator assembly produces one or more phase voltages. A rotor fault detection system is electrically connected to the stator assembly. The rotor fault detection system is operable to detect a rotor fault condition based on a quality of the one or more phase voltages of the stator assembly. An output member is operable to provide a visual output indicating the rotor fault condition is present.

Bearing fault detection system for an alternator

A vehicle system including a plurality of alternators with a common electrical connection interface having at least one connector and a digital communication connector through which a processor communicates with the alternators. Input signals received at the at least one connector are unique for each alternator under normal and unimpaired operating conditions. Upon wakeup of an alternator, the alternator assesses the input signals and whether the address of the alternator is frozen. If the address is not frozen, the status of at least one operating parameter is assessed to determine if a predefined requirement is satisfied. If the predefined requirement is satisfied, the alternator is assigned an address based upon the input signals at the at least one connector and the address is frozen. The alternator can detect faults by determining if the input signals at the least one connector agree with the frozen address of the alternator.

Method and system for freezing alternator node address

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.

System of parallel-connected generators and method for load share balancing therein using a serial communication network

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.

Method for compensating alternator regulation to control remote battery voltage utilizing adaptive variable

An electric motor assembly includes a housing and a stator. The housing includes an outer housing surface, an inner housing surface defining an interior housing cavity, and a plurality of housing protrusions extending from the inner housing surface. The stator is disposed in the inner housing cavity and includes an outer stator surface, an inner stator surface, and a plurality of stator protrusions extending from the outer stator surface toward the outer housing surface. The stator protrusions are configured to mate with the housing protrusions to frictionally couple the stator to the housing in order to fix the stator relative to the housing.

Electric motor assembly and method

An electric motor includes a rotor and a stator. The stator is fixed with respect to the drive-unit housing and includes windings, and the rotor is configured to rotate inside the stator about an axis. An air gap is defined between the rotor and the stator. The electric motor also includes an end-ring fixed to the rotor for rotation therewith. The electric motor is cooled by gravity feed via a fluid flowing onto and past the stator windings, from the windings to the rotor, and from the rotor back to the stator. The end-ring includes an annular channel configured to catch the fluid flowing from the windings to the rotor and divert the fluid away from the air gap as the fluid flows from the rotor back to the stator, thereby limiting spin losses in the electric motor. An electro-mechanical drive-unit employing the above-described electric motor is also disclosed.

Electric motor

A method of manufacturing a squirrel-cage rotor includes: providing a laminated stack; attaching a plurality of rotor bars to the laminated stack, wherein the plurality of rotor bars each include opposite longitudinal ends; and die-casting a pair of end rings at the longitudinal ends of the plurality of rotor bars.

Method of manufacturing squirrel-cage rotor

The present invention provides a method for producing a stator assembly. The method initially includes providing an assembly mandrel having a generally cylindrical hub and a generally annular base circumscribing a terminal end portion of the hub. A first end ring and a stator shell are installed around the mandrel hub and onto the mandrel base. Thereafter, a plurality of poles are disposed on top of the first end ring and in a generally cylindrical pattern between the stator shell and the mandrel hub. A second end ring is disposed around the mandrel hub and on top of the plurality of poles. A plurality of stator shell tabs may then be bent in a radially inward direction to axially retain the first and second end rings.

Method for producing a stator assembly

A permanent magnet machine includes a rotor and a stator including plurality of stator pole sections. Each stator pole section comprises a core section having an inner end piece disposed adjacent to the core section, the inner end piece comprising a first magnetic material that is adapted to saturate during exposure to a first magnetic field strength, and an outer end piece disposed adjacent to the core section radially outwardly relative to the inner end piece, the outer end piece comprising a second magnetic material that is adapted to be unsaturated during exposure to the first magnetic field strength and to saturate during exposure to a second magnetic field strength, wherein the second magnetic field strength is greater than the first magnetic field strength.

Permanent magnet machines with stator pole sections having different magnetic materials

Provided are stir-welded rotors and methods of making these. An exemplary stir-welded rotor may include a stack of laminations that each has spaced-apart slots arrayed on an outer circumference. The slots register with slot bars that each has a first extremity extending above the stack of laminations and a second extremity extending below the stack of laminations. A first weld extends between first extremities of adjacent slot bars, and a second stir weld extending between adjacent second extremities of adjacent slot bars.

Stir-welded rotors and methods of making

The present invention provides a stator assembly for an electromechanical hybrid transmission. The stator assembly is generally annular and defines a centrally located rotor aperture configured to accommodate a rotor. The stator assembly includes a stator core having a plurality of radially inwardly extending stator teeth, and a stator wire wound around each of the stator teeth to form a plurality of stator coils. Epoxy resin is applied between each pair of adjacent stator teeth. The epoxy resin defines a plurality of stator cooling channels located in close proximity to the stator coils, and a plurality of rotor cooling channels located in close proximity to the rotor aperture. A cooling medium is disposed within the stator cooling channels and the rotor cooling channels such that the stator coils and a later assembled rotor can be cooled.

Cooling system for an electric motor

A stator assembly is provided having a generally annular stator core including a plurality of radially inwardly extending stator teeth. A stator wire is wound around each of the plurality of stator teeth to form a plurality of stator coils. Each of the plurality of stator coils are spaced apart to at least partially define a plurality of generally axially extending cooling channels through which a cooling medium, such as oil, flows. Additionally, the plurality of stator teeth each include a respective flanged end portion each adapted to retain an axially extending strip member. The strip member at least partially defines the cooling channel. The cooling medium operates to cool the plurality of stator coils. In the preferred embodiment, at least a portion of the flow of the cooling medium within the cooling channel is turbulent. Additionally, an electromechanical hybrid transmission is disclosed with the stator assembly provided.

Growing community of inventors

Carmel, IN, United States of America

Timothy J Alfermann