Abstract: A belted elevator system (10) includes a hoistway (14) and an elevator car (12) suspended in the hoistway (14) via a suspension member (16) and drivable along the hoistway (14). The suspension member (16) is routed over a plurality of sheaves (18). A sheave (18) of the plurality of sheaves includes a shaft (36) defining a central axis of the sheave (18), the sheave (18) rotatable about the central axis. A sheave outer member (38) is operably connected to the shaft (36) and rotatable about the central axis. The sheave outer member (38) includes a sheave outer surface (44) interactive with the suspension member (16). The sheave outer member (38) is formed from a molded plastic material.

Abstract: A process comprising providing a metallic first powder having a plurality of first particles. The process includes adding a second material to the first powder, the second material having a plurality of second particles. The process includes combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.

Abstract: A method of producing a heat exchanger includes designing the heat exchanger to include a wall with a target thickness. A model is created relating process parameters to geometry of a single track melt pool and relating the single track melt pool geometry to a heat exchanger wall thickness. At least one variable process parameter is defined. The model, heat exchanger wall target thickness, and variable process parameters are used to identify a set of process parameters to produce the heat exchanger wall target thickness. The melt pool geometry is predicted based on the model and process parameters. The heat exchanger wall target thickness is predicted based on the melt pool geometry. The process parameters that will produce the heat exchanger wall target thickness are identified. The additive manufacturing process is controlled based upon the identified set of process parameters to create the heat exchanger wall target thickness.

Abstract: A method of additive manufacturing includes depositing a layer of absorptive material onto a workpiece, depositing a layer of additive manufacturing stock powder onto the workpiece, and fusing the stock powder to the workpiece using a focused energy source at a wavelength wherein the absorptive material has a higher absorptivity at the wavelength of the focused energy source than the absorptivity of the stock powder at that wavelength. The focused energy source can be a laser, e.g., with a 1064 nm wavelength, for example.

Abstract: A process comprising providing a metallic first powder having a plurality of first particles. The process includes adding a second material to the first powder, the second material having a plurality of second particles. The process includes combining the first powder with the second material to form a modified powder including modified powder particles having an interior portion containing an interior composition, and an outer surface portion with an outer composition different from the interior composition.

Abstract: A method of producing a heat exchanger includes designing the heat exchanger to include a wall with a target thickness. A model is created relating process parameters to geometry of a single track melt pool and relating the single track melt pool geometry to a heat exchanger wall thickness. At least one variable process parameter is defined. The model, heat exchanger wall target thickness, and variable process parameters are used to identify a set of process parameters to produce the heat exchanger wall target thickness. The melt pool geometry is predicted based on the model and process parameters. The heat exchanger wall target thickness is predicted based on the melt pool geometry. The process parameters that will produce the heat exchanger wall target thickness are identified. The additive manufacturing process is controlled based upon the identified set of process parameters to create the heat exchanger wall target thickness.

Abstract: A belted elevator system (10) includes a hoistway (14) and an elevator car (12) suspended in the hoistway (14) via a suspension member (16) and drivable along the hoistway (14). The suspension member (16) is routed over a plurality of sheaves (18). A sheave (18) of the plurality of sheaves includes a shaft (36) defining a central axis of the sheave (18), the sheave (18) rotatable about the central axis. A sheave outer member (38) is operably connected to the shaft (36) and rotatable about the central axis. The sheave outer member (38) includes a sheave outer surface (44) interactive with the suspension member (16). The sheave outer member (38) is formed from a molded plastic material.

Abstract: A method of additive manufacturing includes depositing a layer of absorptive material onto a workpiece, depositing a layer of additive manufacturing stock powder onto the workpiece, and fusing the stock powder to the workpiece using a focused energy source at a wavelength wherein the absorptive material has a higher absorptivity at the wavelength of the focused energy source than the absorptivity of the stock powder at that wavelength. The focused energy source can be a laser, e.g., with a 1064 nm wavelength, for example.

Abstract: A winding configuration for an electric machine includes a stator core with a plurality of winding slots, a plurality of conductor strands distributed in a winding slot of the plurality of winding slots, and an insulation matrix that surrounds each of the plurality of the conductor strands. The winding slot includes a slot cavity with a cross-section area and the plurality of distributed conductor strands are configured to maximize slot fill factor.

Abstract: A component to generate a magnetic field and a method of designing windings, comprised of a plurality of strands, within each slot of the component, are described. The component includes a plurality of slots. The component also includes sets of a plurality of strands that form windings, each set of the plurality of strands being enclosed in a respective one of the plurality of slots, each set of the plurality of strands being divided into a plurality of a collection of strands configured to be twisted over a portion of a length of the respective one of the plurality of slots. Each of the collection of strands changes cross sectional shape over the portion.

Abstract: In one embodiment, a stator includes a stator core and a winding assembly. The stator core has an axis and a slot extending a radial depth from a slot opening. The winding assembly is disposed in the slot, and includes a plurality of winding strands with cross-sectional shapes that vary as a function of radial location within the slot. In another embodiment, a method of forming a stator winding assembly for a stator slot includes additively manufacturing a plurality of winding strands and an insulating gap matrix that separates the winding strands. The winding strands have cross-sectional shapes through a radial-circumferential plane that varies as a function of radial position within the slot.

Abstract: A refrigerated cargo container includes a refrigeration unit and a cargo container. The refrigeration unit includes a support frame formed from at least one layer of composite material and at least one layer of insulative foam material. The support frame is supportive of one or more components of the refrigeration unit and insulative of a cargo portion of the cargo container.

Abstract: An electric machine includes a laminated stack. The laminated stack includes first and second additively manufactured conductive phase coils. Each of the first and second additively manufactured phase coils includes of a plurality of conductive strands. An additively manufactured end winding conductively couples the first and second phase coils. The end winding has a non-circular cross-sectional geometry.