Abstract: A stator of a rotary electric machine having secured core slot insulators includes a multi-phase stator winding, having a plurality of slot segments that are adapted to be radially inserted into a plurality of circumferentially spaced axially-extending core slots in a surface of a cylindrically-shaped stator core. The stator winding includes the plurality of slot segments alternately connected at the first and second ends of the stator core by a plurality of end loop segments to form the winding. The plurality of core slots house an insulator to electrically isolate the slot segments from the core slots. The insulator is secured to the sides of the core slot prior to the process of radial inserting the plurality of slot segments into the plurality of core slots of the cylindrically-shaped stator core.

Abstract: Disclosed is a coil support for an electrical machine including a shank having a first outer diameter configured to support a field coil of the electrical machine and a base located at one end of the shank. The base has a second outer diameter greater than the first outer diameter and includes a plurality of recesses configured to increase a cooling flow through the electrical machine. Further disclosed is an electrical machine including the coil support and a method for cooling an electrical machine.

Abstract: An electric motor core member includes a body having an inner diametric portion including an inner arcuate surface and an outer diametric portion including an outer arcuate surface. The electric motor core member further includes a plurality of wall members provided on the main body. Each of the plurality of wall members projects outwardly from the outer arcuate surface and is arranged in a spaced relationship to define a plurality of conductor isolation channels. Each of the plurality of conductor isolation channels is adapted to receive one of a plurality of conductors with the plurality of wall members providing electrical isolation between adjacent ones of the plurality of conductors.

Abstract: An alternator comprises a regulator configured to control the electric current to a field coil. The regulator includes a field driver circuit, the field driver circuit configured to deliver the electric current to the field coil at a switching frequency. The regulator further includes a controller configured to vary the switching frequency of the field driver circuit between a plurality of different switching frequencies. The alternator further comprises a sensor configured to detect a predetermined alternator condition, and the controller is configured to adjust the switching frequency of the field driver circuit in response to the sensed predetermined condition such as, for example, a rotor speed, a pulse width from the field driver circuit, an efficiency of the alternator, a temperature within the alternator, a temperature outside of the alternator, or magnetic noise of the alternator.

Abstract: An apparatus for winding wire about a tooth of a core includes an amount of wire, a winding member configured to receive a portion of the amount of wire, and a winding device operatively coupled to the winding member. The winding device being configured to apply a number of wraps of the amount of wire to at least one of a plurality of teeth of the core. The number of wraps including a number of twists that is fewer than the number of wraps.

Abstract: A dynamoelectric machine grommet including, a body portion of the grommet sealably engagable with an opening in a housing of a dynamoelectric machine, and at least one projection extending from the body portion and receptive to a conductor and providing electrical insulation thereto.

Abstract: A method of winding a flexible core includes forming a flexible core member having a first end portion, a second end portion and a plurality of teeth each having a central axis with the plurality of teeth being arranged in a substantially linear array. The method also includes manipulating the flexible core member into an inverted core form having an outer portion and an inner portion with the plurality of teeth extending out from the outer portion away from the inner portion, positioning a winding member including an amount of wire adjacent one of the plurality of teeth, and rotating the flexible core member about the central axis of the one of the plurality of teeth. The method further includes applying wraps of the wire to the one of the plurality of teeth.

Abstract: Disclosed herein is a brushless electric machine comprising, a housing, a stationary field coil, a shaft, a bearing, a pole segment, and a stator. The stator including a core having a plurality of core slots that extend between a first and a second end of the stator core. The stator also including a winding with a plurality of phases, each of the phases having at least one conductor having a plurality of substantially straight segments disposed in the core slots. The straight segments are alternately connected at the first and the second ends of the stator core by a plurality of end loop segments. A section of at least one of the conductors including three consecutive end loop segments and two straight segments, is formed from a single continuous conductor, and one of the core slots houses a plurality of the straight segments arranged in at least one radial row.

Abstract: Disclosed herein is a rotor assembly for an electric machine including a stationary shaft, a first bearing, a second bearing, a first pole segment, a second pole segment, a first internal fan, and a second internal. The first bearing is positioned at a first end of the shaft. The second bearing is positioned at a second end of the shaft. The first pole segment is supported by the first bearing and is rotatable about the shaft. The second pole segment is supported by the second bearing and is rotatable about the shaft. The first internal fan is attached to the first pole segment. And, the second internal fan is attached to the second pole segment.

Abstract: A twisting device comprises at least one conductor coupler configured to engage a plurality of the conductors and at least one drive operably connected to the conductor coupler. The at least one drive is configured to rotate the conductor coupler in order to bend the plurality of the conductors and simultaneously move the conductor coupler in an axial direction relative to the electric machine component. An associated method of bending conductors positioned in a component of an electric machine comprises first engaging a plurality conductors with a conductor coupler. Thereafter, the plurality of conductors are bent by rotating the conductor coupler while simultaneously moving the conductor coupler in an axial direction relative to the component of the electric machine.

Abstract: The disclosed apparatus relates to a current sensing electrical energy generation system comprising, an electric machine, a conductor electrically connected to the electric machine, and a current sensor responsive to current flow in the conductor.

Abstract: An improvement to a bridge rectifier assembly of the type used to convert alternating current produced by an motor vehicle alternator into direct current. The bridge rectifier assembly of this type comprises a heat sink, a plurality of pressfit diodes installed in the heat sink, and a plurality of terminals electrically connected to the motor vehicle alternator. The first end of a flexible conductor is mechanically and electrically connected to a conductive connector. The second end of the flexible conductor is mechanically and electrically connected to a lead of one of the plurality of pressfit diodes. The conductive connector is electrically connected to one of the plurality of terminals to complete an electrical connection between the one of the plurality of pressfit diodes and the one of the plurality of terminals.

Abstract: An electric machine comprises a stator core defining a plurality of slots. Multi-phase fractional slot windings are positioned in the slots of the stator core. The multi-phase winding include a first winding set comprised of a first plurality of conductors having a substantially rectangular cross-sectional shape and a second winding set comprised of a second plurality of conductors having a substantially rectangular cross-sectional shape. The multi-phase fractional slot windings include a non-integer slots per pole per phase value.