Abstract: Systems and methods for adjusting outputs of dynamoelectric devices, such as alternators, are provided. The outputs of the dynamoelectric devices may be balanced to facilitate load sharing among the devices. The outputs may be balanced by monitoring field signals associated with the dynamoelectric devices and controlling the field voltages of the devices. The outputs may also be adjusted to supply the load in dissimilar proportions.

Abstract: A vent assembly is provided for allowing internal contaminants to exit a solenoid. The vent assembly includes a vent membrane interposed between a gasket and a support. The support may have a variable diameter. The vent assembly attaches to the solenoid via a mating cover of the solenoid, which includes a vent opening that aligns with an opening in the gasket and includes a counter bore that captures the gasket. The vent assembly allows contaminants to exit the solenoid through a vent membrane. It also prevents contaminants from entering the solenoid around the vent membrane without the use of injection molding.

Abstract: An internal cooling fan assembly for use with a claw-pole segment of a rotor assembly is provided that maximizes air flow while providing a reduced sound signature. The fan assembly includes a base portion that contacts the claw-pole segment when the fan assembly is mounted to the claw-pole segment. The fan assembly also includes a number of blades extending from the base portion such that the blades project outward from a plane normal to the rotor. The plurality of blades have a geometry that aligns with roots of the claw-pole segment. In addition, a first blade of the number of blades is of a first configuration and a second blade of the number of blades is of a second configuration different from the first configuration.

Abstract: Methods, systems, and articles of manufacture for fastening internal cooling fans to claw-pole segments are provided. A claw-pole segment suitable for use in a rotor of an electro-mechanical machine is formed. The claw-pole segment may include a base portion, at least one claw pole projecting axially from the base in a first direction, and at least one protrusion projecting axially from the base in a second direction opposite the first direction. A fan assembly that attaches to the claw-pole segment is also formed. The fan assembly may include at least one opening for receiving the at least one protrusion, and may be formed with varying configurations to affect the frequency response of the fan. The portion of the at least one protrusion extends through and beyond the opening of the fan assembly when the fan assembly is mounted on the claw-pole segment and expands in response to an application of an axial load, to secure the fan assembly to the claw-pole segment.

Abstract: A power module is connected to the starter, alternator, and battery for an internal combustion engine. The power module includes one or more capacitors and delay timer. When the ignition switch closes, the battery of the starting system provides current to the starter motor, causing the starter solenoid to close the starter contacts, and bring a starter pinion gear into engagement with a flywheel ring gear. The delay timer does not allow the capacitor to immediately deliver current to the starter motor, but implements a short delay before the capacitor's current is released to the starter motor. This short delay increases the chance for full engagement between the starter pinion and the flywheel ring gear, thereby reducing the likelihood of milling when the starter motor provides torque to the starter pinion.

Abstract: An electric machine having multi-set rectangular copper hairpin windings comprises a stator having a plurality of partially closed stator slots. A first winding set and a second winding set are positioned in the stator slots. The first winding set and the second winding set are connected by adjacent leg ends. According to a first embodiment, conductor layers in alternate slots alternate between different phases. The conductor layers in the remaining slots are all of the same phase. Hairpins having unequal length legs are used to implement the first embodiment. According to a second embodiment, conductor layers in alternate slots include one phase for the first winding set and another phase for the second winding set. The conductor layers in the remaining slots are all of the same phase. Hairpins having equal length legs are used to implement the second embodiment.

Abstract: A method for controlling voltages in an integrated starter alternator electric machine is provided where the armature windings are manipulated in a ?/Y/? fashion. In particular, the armature windings are arranged in a ? connection during engine cranking operation, when the electric machine acts as a starter motor. After the engine is cranked, the windings are changed into a Y connection when the ISAD machine changes from motoring to generating and operates a low speeds, such as idle speed. Next, when the engine speed increases above a predetermined winding reconfiguration speed, the windings are switched from Y to ? connection. If the engine speed falls below the winding reconfiguration speed, the machine again switches the armature windings to a Y connection to take advantage of the efficiencies of the Y connection at that low speed range in the generating state.

Abstract: An electric machine having multi-set rectangular copper hairpin windings comprises a stator having a plurality of partially closed stator slots. A first winding set and a second winding set are positioned in the stator slots. The first winding set and the second winding set are connected by adjacent leg ends. According to a first embodiment, conductor layers in alternate slots alternate between different phases. The conductor layers in the remaining slots are all of the same phase. Hairpins having unequal length legs are used to implement the first embodiment. According to a second embodiment, conductor layers in alternate slots include one phase for the first winding set and another phase for the second winding set. The conductor layers in the remaining slots are all of the same phase. Hairpins having equal length legs are used to implement the second embodiment.

Abstract: A power module is connected to the starter, alternator, and battery for an internal combustion engine. The power module includes one or more capacitors and delay timer. When the ignition switch closes, the battery of the starting system provides current to the starter motor, causing the starter solenoid to close the starter contacts, and bring a starter pinion gear into engagement with a flywheel ring gear. The delay timer does not allow the capacitor to immediately deliver current to the starter motor, but implements a short delay before the capacitor's current is released to the starter motor. This short delay increases the chance for full engagement between the starter pinion and the flywheel ring gear, thereby reducing the likelihood of milling when the starter motor provides torque to the starter pinion.

Abstract: A one-piece stator lead and terminal insulator for an oil cooled alternator comprises an arcuate plate having three cylindrical retainers positioned thereon for receiving stator terminals. The arcuate plate also includes three guides for guiding stator leads to the terminals. Furthermore, three rectangular holes are provided next to each of the guides. The rectangular holes receive insulating ties that encircle the stator leads and hold the stator leads to the plate, properly positioning the stator leads away from other conductors and housings within the alternator. Two flanges also extend from the plate to aid in assembly of the device and further act to properly position the stator leads away from other conductors and housings within the alternator.