Abstract: A solenoid for a vehicle starter comprises a spool including a first coil bay, a second coil bay, and an interior passage defining an axial direction. A first coil is positioned in the first coil bay of the spool, and a second coil positioned in the second coil bay of the spool. A plunger is positioned within the interior passage of the spool and configured to move in the axial direction when the first coil is energized. The first coil bay is positioned adjacent to the second coil bay in the axial direction. The spool further includes two end flanges and a middle flange. The middle flange separates the first coil bay from the second coil bay.

Abstract: A solenoid for a vehicle starter includes a pull-in coil made of a length of rectangular wire and a hold-in coil adjacent to the pull-in coil. A plunger is configured to move in an axial direction when the pull-in coil made of rectangular wire is energized. The pull-in coil and the hold-in coil are positioned on a spool with the plunger slideably positioned within a central passage of the spool. The plunger is configured to engage a plunger stop when the pull-in coil is energized. In at least one embodiment, the hold-in coil is separated from the plunger stop in the axial direction and the hold-in coil encircles the plunger stop.

Abstract: A solenoid for a vehicle starter includes at least one coil with a passage extending through the coil. A plunger is slideably positioned within the passage and configured to move in an axial direction between a first position and a second position. The plunger includes a substantially cylindrical outer surface portion with a circumferential notch formed in the outer surface portion. The at least one coil may include a pull-in coil and a hold-in coil wound on a spool. A plate member is positioned at one end of the spool and is separated from the plunger by a radial distance. The radial distance varies when the plunger moves in the axial direction as a result of the notch moving in relation to the plate member. A sleeve member may be coupled to the plunger such that the sleeve member covers the circumferential notch formed in the plunger.

Abstract: A solenoid for a vehicle starter comprises a pull-in coil and a hold-in coil positioned axially adjacent to the pull-in coil. A plunger is positioned within the pull-in coil and configured to move in an axial direction when the pull-in coil is energized. The plunger is separated from a plunger stop in the axial direction by an air gap when the pull-in coil and the hold-in coil are not energized. When the pull-in coil and hold-in coil are energized, a shoulder of the plunger moves in an axial direction toward the plunger stop. The pull-in coil is positioned in the solenoid such that it is removed from the plunger stop in the axial direction. In contrast, the hold-in coil encircles the plunger stop.

Abstract: An electric machine includes a core with a plurality of slots. Electric conductors are positioned within the slots with connection ends extending from the in-slot portions. A plurality of insulation sleeves separate the plurality of electric conductors. Each insulation sleeve substantially covers one entire conductor, including the in-slot portions and the connection ends of the conductor. A tip portion on each connection end remains uncovered by the insulation sleeve and is electrically connected to another tip portion on another conductor. Air passages are formed between the plurality of insulation sleeves at the in-slot portions and at the connection ends of the plurality of electric conductors.

Abstract: A solenoid arrangement for a starter motor includes a plunger configured to move in an axial direction and a coil positioned radially outward from the plunger. The coil is wound on a spool that includes a first end and a second end with a hub extending between the first end and the second end. A projection is positioned on the hub of the spool. The coil engages the projection in such a manner that a winding direction of the coil is reversed at the projection.

Abstract: A vehicle alternator comprises a rotor and a stator positioned within a housing. The housing includes a front face, a rear face, and a outer wall extending between the front face and the rear face. The front face includes a plurality of air inlet holes, and the rear face including a plurality of air outlet holes. The outer wall is void of air holes that extend through the outer wall. The rotor is positioned within the housing and configured to rotate about an axis. The stator is positioned within the housing between the rotor and the outer wall of the housing. The stator includes a core with an outer surface, a front end and a rear end. A plurality of substantially axial air passages are positioned between the outer wall of the housing and the outer surface of the stator core.

Abstract: An electric machine includes a stator and a rotor configured to rotate about an axis of rotation in a direction of angular rotation. The rotor includes a first claw-pole segment and an opposing second claw-pole segment. The first claw-pole segment includes a plurality of fingers extending from an end ring. Each finger includes a distal end and a proximal end with the proximal end fixed to the end ring. Each finger also includes an interior side and an exterior side with the exterior side facing the stator. A leading side and a trailing side are defined on each finger by the direction of angular rotation. A chamfer is formed on the exterior trailing side of each finger at the proximal end of the finger.

Abstract: An electrical system for a vehicle comprises a battery including a positive terminal and a negative terminal, and an alternator. The alternator includes a metal housing with a rotor and a stator positioned within the housing. The alternator further includes an electronics package positioned on the alternator housing. The electronics package includes a regulator and a rectifier, the rectifier including a plurality of negative diodes and a plurality of positive diodes. The plurality of positive diodes are positioned on a first diode carrier that is electrically connected to the negative terminal of the battery. The plurality of positive diodes are positioned on a second diode carrier that is electrically connected to the positive terminal of the battery. The first diode carrier is separated from the housing by an electrical insulation member positioned between the first diode carrier and the housing.

Abstract: Disclosed is an improved stator for a dynamoelectric machine including a stator core which has a plurality of core slots extending axially from a first end of the stator core to a second end of the stator core. The stator also includes a stator winding having a plurality of phases. Each phase of the stator winding includes at least a first filar. The first filar extends around the stator core and form a plurality of layers and has a plurality of slot segments disposed in the plurality of core slots. The slot segments are alternately connected at the first and second ends of the stator core by a plurality of end loop segments. The slot segments are configured such that at least two consecutive slot segments are disposed in substantially the same radial position relative to additional slot segments of the plurality of slot segments disposed in the respective core slots, and the at least two consecutive slot segments are disposed at differing radial distances from a central axis of the stator core.

Abstract: An electric machine is disclosed herein comprising a stator and a rotor opposing the stator. A plurality of slots are formed in the rotor, each of the plurality of slots including a stator side and an opposing side. Each of the plurality of slots further include a central magnet retaining portion positioned between two opposing end portions of the slot. The central magnet retaining portion is defined by at least one protrusion formed on the stator side of the slot. The at least one protrusion forms a neck in the slot and separates the magnet retaining portion from one of the end portions. A magnet is positioned in the magnet retaining portion of the slot. The two opposing end portions of the slot are empty, providing voids at the ends of the slot.

Abstract: A winding apparatus for a segmented core having a plurality of stator teeth includes a mounting fixture configured to support select ones of the plurality of stator teeth. The mounting fixture is configured to rotate about an axis defined by each of the plurality of stator teeth. The winding apparatus also includes a plurality of stator tooth holding elements operatively connected to the mounting fixture. Each of the plurality of stator tooth holding elements are configured to retain a select one of the plurality of a stator teeth relative to the mounting fixture. The mounting fixture is selectively rotated about the axis of at least one of the plurality of teeth to apply wraps of wire to the one of the plurality of stator teeth while at the same time rotating others of the plurality of stator teeth that have already been wrapped with wire.

Abstract: A dynamoelectric machine conductor includes a bus including a central portion, a first connectable site of the central portion connectable with a first conductor and a first arm having a second electrically connectable site connectable with a second conductor. A first fused portion of the first arm located between the first connectable site and the second connectable site, the first fused portion being electrically interruptible to open a circuit between the first connectable site and the second connectable site. A second arm having a third connectable site connectable with a third conductor, and a second fused portion of the second arm located between the first connectable site and the third connectable site. The second fused portion being electrically interruptible to open a circuit between the first connectable site and the third connectable site.

Abstract: An engine starter comprises a housing with a planetary gear arrangement provided within the housing. The planetary gear arrangement includes a ring gear configured to pivot about an axis. The ring gear includes a face oriented substantially perpendicular to the axis, the face including a plurality of detents provided as a plurality of ribs and a plurality of depressions on the face. A torque limiter is positioned adjacent to the face of the ring gear within the housing of the engine starter. The torque limiter includes a plurality of projecting members engaging the plurality of detents on the ring gear when the ring gear pivots about the axis. The torque limiter is provided as a plate including a central hole, a body portion, and a perimeter portion. The plurality of projecting members comprise a plurality of spring fingers extending from the body portion at an angle.

Abstract: A starter solenoid comprises a solenoid cap defining a contact channel. A first terminal and a second terminal are provided on the solenoid cap. A contact is moveable within the channel between a first position where the contact touches the first and second terminals and a second position where the contact is removed from the first and second terminals. A shield is positioned in the channel to space the contact apart from the channel walls. The contact comprises a first terminal face connected to a second terminal face. The first and second terminal faces are configured to respectively contact the first and second terminals when the contact is in the first position. Opposing lips extend from opposite sides of the first terminal face with a curved shoulder provided between the first terminal face and each of the opposing lips.

Abstract: Disclosed is an apparatus for forming a wire to include coil segments useable in a dynamoelectric machine, the apparatus including a plurality of forming structures simultaneously moveable along an axis into a coil segment forming configuration, with at least a number of the plurality of forming structures being configured to hold a wire, and at least one actuating device associated with at least a number of the plurality of forming structures and configured to simultaneously move the number of the plurality of forming structures into the coil segment forming configuration.

Abstract: A method for implementing voltage regulation for an electrical generator device includes comparing an output voltage of the electrical generator device to a desired set point voltage thereof, and generating an output control signal configured to regulate a field current of the generating device. The output control signal is generated in accordance with a linear mode of operation during of one of an overvoltage condition and an undervoltage condition with respect to the desired set point voltage, and wherein the output control signal is automatically set to a predetermined value in a non-linear mode of operation during the other of the overvoltage condition and the undervoltage condition.

Abstract: The apparatus disclosed herein relates to a pole piece for an electric machine comprising, a pole piece with a finger support structure, a plurality of fingers having an axial component of extension relative to the finger support structure, a coil contact surface and at least one of a protrusion or a depression having an axial component of extension relative to the coil contact surface. Further disclosed is a method that relates to assembling a coil to pole pieces comprising, axially compressing a coil between coil contact surfaces of a pair of opposing pole pieces and deforming the coil axially and without radial deformation with at least one of protrusions and depressions in the coil contact surfaces of the pole pieces thereby rotationally fixing the coil to the pole pieces.

Abstract: Disclosed is an improved stator for a dynamoelectric machine including a stator core which has a plurality of core slots extending axially from a first end of the stator core to a second end of the stator core. The stator also includes a stator winding having a plurality of phases. Each phase of the stator winding includes at least a first filar. The first filar extends around the stator core and form a plurality of layers and has a plurality of slot segments disposed in the plurality of core slots. The slot segments are alternately connected at the first and second ends of the stator core by a plurality of end loop segments. The slot segments are configured such that at least two consecutive slot segments are disposed in substantially the same radial position relative to additional slot segments of the plurality of slot segments disposed in the respective core slots, and the at least two consecutive slot segments are disposed at differing radial distances from a central axis of the stator core.

Abstract: Disclosed is a dynamoelectric machine having improved heat dissipation capabilities. The dynamoelectric machine includes a three-phase stator winding with a rectifier assembly electrically connected to the stator winding. The rectifier assembly includes an end frame having at least one negative diode contained therein and a positive heat sink which has at least one positive diode disposed therein. Connecting the negative diodes and positive diodes is a terminal assembly. The terminal assembly includes one or more electrically conductive and heat dissipative straps. The straps electrically connect one or more negative diodes and one or more positive diodes. Also disclosed is a method for dissipating heat from a rectifier of a dynamoelectric machine.