Abstract: An electrical alternator includes a stator with circumferentially-spaced stator arms, each having a coil wound on it. The rotor includes a cup-shaped support component with a plurality of magnets affixed to the inner surface of the component rim so as to be in excitation relationship to the coils. The improvement comprises a hub including (a) a first hub portion having the stator affixed thereto, and (b) a second hub portion axially spaced from the first hub portion. A ribbed section is affixed to the hub between the hub portions and includes a primary mount and two auxiliary mounts. The primary mount is bolted to an engine block. The alternator affords a high degree of mounting flexibility in that the alternator can be mounted toward the left or right of the engine and either one of the auxiliary mounts used for alternator attachment to a mounting bracket. Novel cooling and voltage regulator mounting arrangements are also disclosed.

Abstract: An apparatus has first and second driven pulleys for powering an engine auxiliary function, e.g., a water pump, and for driving an engine fan, respectively. The apparatus includes a hollow tube-like arbor fixed with respect to the first pulley and having a first arbor surface, e.g., an exterior cylindrical surface. A bearing has a first load-supporting surface, e.g., the interior surface of the bearing, which is mounted to the first arbor surface. A fan drive member is mounted to the second load-supporting surface of the bearing, e.g., the exterior bearing surface, and both the fan and the second pulley are coupled to the fan drive member. The two pulleys are driven by respective belts powered by the engine crankshaft and the pulleys rotate in opposite directions when driven. A new engine incorporating the apparatus is also disclosed.

Abstract: A "hot start" method for arc welding includes selecting a first weld current, setting a time interval, striking an arc, flowing a second, higher weld current through the welding rod and then, after a brief time interval, reducing the current through the rod to the value of the first weld current. Also disclosed is a new arc welder stator having two groups of slots around a core. The group of larger slots contains the weld current windings and slots in the group of smaller slots contain windings for timing, gate voltage, battery charging, auxiliary power and the like. A new cooling apparatus for an arc welder has an air duct and a "double-bladed" fan for flowing air along several paths and cooling both the welder control section and the generating section. A new method for electronically controlling engine speed in an engine-driven arc welder is also disclosed.

Abstract: A permanent magnet alternator includes a stator core having outwardly projecting teeth and further includes a plurality of permanent magnets surrounding the stator core. The stator core is formed from a continuous, helically wound metallic strip having a plurality of teeth defined between slots formed in one edge thereof. The stator core is formed by winding the strip edgewise around a cylindrical mandrel. To facilitate winding and avoid distortion, arcuate regions, conforming to the curve of the mandrel, are formed in the strip opposite the teeth.

Abstract: In an engine-generator set, the generator has a first shaft driving a generator armature and also has a second shaft in spaced relationship to the first shaft. The second shaft is coupled to the engine and there is a gear on each of the shafts which provides a "step-down" gear reduction for powering the generator at, e.g., 1800 rpm, where the engine speed is greater than 1800 rpm. Preferably, the engine is coupled to the generator armature shaft through a torsional coupling for isolating engine vibration from the generator.

Abstract: A method for making a power-transmitting coupling including the steps of forming first and second "half-shell" coupling components, each of which has an edge around the component cavity and also has a number of radially-outwardly-extending projections. The components are supported on a hub in edge-contacting relationship to one another and then such components are joined to one another and to the hub. A new power-transmitting coupling is also disclosed.

Abstract: A flow-responsive diverting valve is particularly useful with pressure washers of the type having a water pump coupled to an internal combustion engine equipped with a pull-rope starter. The valve provides an "easy-start" feature and has a valving chamber and a fluid inlet and two fluid outlets. A magnet is fixed on the valve body and when fluid flows into the inlet at the low flow rate occurring when operating the starter, a valving device, e.g., a check ball, is restrained by the magnet. When fluid flows into the inlet at a higher flow rate (as when the engine is running and the pump is delivering water at a substantial rate), the device closes the first outlet and diverts water to the second outlet. A method for operating a pressure washer includes magnetically restraining the valving device away from the first outlet while operating the starter and then running the engine, thereby urging the device to close the first outlet.

Abstract: An engine-driven generator having a battery powered starter motor includes a permanent magnet battery charger/pre-exciter for charging the starting battery and for exciting the main alternator field winding of an AC synchronous alternator included in the engine-driven generator. A first winding in the permanent magnet battery charger/pre-exciter provides power to a first voltage regulator that, in turn, maintains a desired load voltage substantially independently of alternator loading. A second winding within the permanent magnet battery charger/pre-exciter supplies power to a second voltage regulator that maintains a desired battery charging voltage substantially independently of the alternator loading. Use of the permanent magnet battery charger/pre-exciter maintains a desired battery charge current and a desired main alternator field excitation substantially independently of the load current supplied by the alternator.

Abstract: An engine-driven generator includes an internal combustion engine, a permanent magnet alternator and an AC to AC converter. The output frequency and voltage of the permanent magnet alternator are largely dependent on engine speed and the alternator load. The AC to AC converter converts the speed-dependent alternating potential developed by the alternator to another alternating potential whose frequency and voltage are largely independent of engine speed. Voltage regulation is provided by varying the engine speed in accordance with the load current. Frequency regulation is provided by frequency dividing the alternator output by an integer divisor that varies in accordance with engine speed. Additional voltage regulation is provided by deleting selected cycles of the alternator output current as needed to maintain the RMS output voltage within predetermined limits.

Abstract: An internal combustion engine for portable power generating equipment includes a camshaft assembly having an integral oil pump at one end thereof. The camshaft, which is preferably formed of two dissimilar materials, is mounted for axial movement in response to increased oil pressure so as to provide automatic oil pressure regulation. Structure is provided for reducing engine compression at low speeds to reduce cranking resistance during starting. Speed control is provided by a stepper motor coupled through a cam to the engine throttle. The cam is shaped so as to counteract the non-linear relationship between throttle position and engine power and speed so as to provide a desired relationship between the position of the stepper motor and the engine power and speed.

Abstract: A permanent magnet alternator includes a stator core having outwardly projecting teeth and further includes a plurality of permanent magnets surrounding the stator core. The stator core is formed from a continuous, helically wound metallic strip having a plurality of teeth defined between slots formed in one edge thereof. The stator core is formed by winding the strip edgewise around a cylindrical mandrel. To facilitate winding and avoid distortion, arcuate regions, conforming to the curve of the mandrel, are formed in the strip opposite the teeth.

Abstract: An engine-driven generator includes an internal combustion engine, a permanent magnet alternator and an AC to AC converter. The output frequency and voltage of the permanent magnet alternator are largely dependent on engine speed and the alternator load. The AC to AC converter converts the speed-dependent alternating current developed by the alternator to another alternating current whose frequency and voltage are largely independent of engine speed. Voltage regulation is provided by varying the engine speed in accordance with the load current. Frequency regulation is provided by frequency dividing the alternator output by an integer divisor that varies in accordance with engine speed. Additional voltage regulation is provided by deleting selected cycles of the alternator output current as needed to maintain the RMS output voltage within predetermined limits.

Abstract: An internal combustion engine for portable power generating equipment includes a camshaft assembly having an integral gerotor oil pump at one end thereof. The camshaft, which is preferably formed of two dissimilar materials, is mounted for axial movement in response to increased oil pressure so as to provide automatic oil pressure regulation. Structure is provided for reducing engine compression at low speeds to reduce cranking resistance during starting. Speed control is provided by a stepper motor coupled through a cam to the engine throttle. The cam is shaped so as to counteract the non-linear relationship between throttle position and engine power and speed so as to provide a desired relationship between the position of the stepper motor and the engine power and speed.