Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A parallel generator system having a plurality of parallel-connected generator units and a controller for selective activation and deactivation of generator units, wherein generator units are selectively activated and deactivated by the controller based on system efficiency level and the number of active generator units, and a method for using a controller to selectively activate and deactivate generator units based on system efficiency level and the number of generator units, in a parallel generator system.

Abstract: A parallel generator system having at least one controller using selective load reduction for load share balancing, and a method for using selective load reduction for load share balancing in a parallel generator system.

Abstract: A parallel generator system having a controller using an accumulated damage model for load share balancing, and a method for using an accumulated damage model for load share balancing in a parallel generator system.

Abstract: 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.

Abstract: 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.