Abstract: A rotor assembly is disclosed for use with an alternator. The rotor assembly includes a bobbin assembly, a claw pole assembly having an integrated hub on which the bobbin assembly is positioned, a shaft that is received in the claw pole assembly, and a slipring assembly connected to the shaft. The bobbin assembly includes thin first and second end caps, a metal sleeve, a ring of inner tape, a field coil, and a ring of outer tape. The first and second end caps each have inner and outer flaps. The inner flaps are folded inwardly so that the end caps fit over the metal sleeve. The ring of inner tape is wrapped around the inner flaps of both end caps to adhere the first and second end caps to the metal sleeve. The field coil is wrapped around the inner ring of tape, inner end caps, and metal sleeve. The outer flaps on the end caps are inwardly folded around the field coil. The ring of outer tape is adhered to the folded outer flaps and the field coil.

Abstract: A rotor assembly is disclosed for use with an alternator. The rotor assembly includes a bobbin assembly, a claw pole assembly having an integrated hub on which the bobbin assembly is positioned, a shaft that is received in the claw pole assembly, and a slipring assembly connected to the shaft. The bobbin assembly includes thin first and second end caps, a metal sleeve, a ring of inner tape, a field coil, and a ring of outer tape. The first and second end caps each have inner and outer flaps. The inner flaps are folded inwardly so that the end caps fit over the metal sleeve. The ring of inner tape is wrapped around the inner flaps of both end caps to adhere the first and second end caps to the metal sleeve. The field coil is wrapped around the inner ring of tape, inner end caps, and metal sleeve. The outer flaps on the end caps are inwardly folded around the field coil. The ring of outer tape is adhered to the folded outer flaps and the field coil.

Abstract: A rotor for an alternator is provided which has the benefits of a thin bobbin, as well as the benefits of a single contact steel core, thereby increasing the dissipation of heat and maximizing the space for winding the field coil to increase the overall power provided by the rotor and alternator. The rotor includes a bobbin assembly having a hollow cylinder with a first end and a second end, a first end cap attached to the first end of the cylinder and a second end cap attached to the second end of the cylinder. The bobbin assembly further includes a metallic sleeve fitted inside the hollow cylinder and providing support to the hollow cylinder.

Abstract: A rotor for an alternator is provided which has the benefits of a thin bobbin, as well as the benefits of a single contact steel core, thereby increasing the dissipation of heat and maximizing the space for winding the field coil to increase the overall power provided by the rotor and alternator. The rotor includes a bobbin assembly having a hollow cylinder with a first end and a second end, a first end cap attached to the first end of the cylinder and a second end cap attached to the second end of the cylinder. The bobbin assembly further includes a metallic sleeve fitted inside the hollow cylinder and providing support to the hollow cylinder.

Abstract: An alternator for a motor vehicle is disclosed. The alternator includes a stator having a stator winding, a rotor assembly positioned concentrically relative to the stator, and including at least one pole having an outer surface. The outer surface has a groove and includes a field coil disposed adjacent the at least one pole, the field coil having start and end leads. A slip ring is fixedly coupled to the start and end leads and a rotor shaft on which the field coil, the at least one pole and the slip ring are fixed. Moreover, the start and end leads are positioned within the groove and are retained in the groove by a locking feature formed in the outer surface of the at least one pole.

Abstract: An alternator rotor assembly 30 is provided, including a rear pole piece 34 having a rear pole base portion 58 and a plurality of rear pole finger portions 60 each having a rear pole fingertip 62. The plurality of rear pole finger portions 60 are positioned to form a plurality of rear pole finger gaps 64. The alternator rotor assembly 30 further includes a front pole piece 32 having a front pole base portion 50 and a plurality of front pole finger portions 52 each having a front pole fingertip 54. The plurality of front pole finger portions 52 are positioned to form a plurality of front pole finger gaps 56. The rear pole piece 34 and the front pole piece 32 are assembled such that the rear pole finger portions 60 are positioned within the front pole finger gaps 56 and the front pole finger portions 52 are positioned within the rear pole finger gaps 64. The alternator rotor assembly 30 further includes a plurality of link elements 70.

Abstract: A rotor assembly for an alternator includes an electrical wire defining an excitation winding. A first pole piece and a second pole piece each have a generally circular body defining an axis of rotation and an outer radial periphery. A plurality of pole fingers are spaced radially about and extend axially from the outer radial periphery of each pole piece parallel to the axis of rotation. Each pole piece includes a plurality of mounting surfaces spaced radially about the outer radial periphery between the pole fingers. A plurality of permanent magnets are positioned on the mounting surfaces. A plurality of covers include tabs extending therefrom and are adapted to substantially encase one of the permanent magnets. The mounting surfaces of the first and second pole pieces include ribs which are adapted to engage the tabs to secure the covers to the mounting surfaces.

Abstract: A rotor assembly for an alternator includes an electrical wire defining an excitation winding. A first pole piece and a second pole piece each have a generally circular body defining an axis of rotation and an outer radial periphery. A plurality of pole fingers are spaced radially about and extend axially from the outer radial periphery of each pole piece parallel to the axis of rotation. Each pole piece includes a plurality of mounting surfaces spaced radially about the outer radial periphery between the pole fingers. A plurality of permanent magnets are positioned on the mounting surfaces, each of the permanent magnets being secured to the pole pieces by a threaded fastener extending therethrough and engaging the pole pieces.

Abstract: An alternator rotor prevents the field coil from moving within the rotor assembly in a manner that increases the power density of the alternator. The structure maximizes the available space for the field coil and provides increased dissipation of heat to accomplish the same. Preferably, the outer diameter of the field coil is greater than or equal to the inner diameter of the first and second pole pieces for frictional engagement of the coil assembly to the first and second pole pieces. In this manner, the field coil is compressed to form depressions corresponding to the pole pieces to prevent rotation.

Abstract: An alternator fan having a generally disc-shaped body with opposed first and second faces. The body includes a plurality of ribs that define raised peaks on the first face and recessed valleys on the second face.

Abstract: An alternator for a motor vehicle is disclosed. The alternator includes a stator having a stator winding, a rotor assembly positioned concentrically relative to the stator, and including at least one pole having an outer surface. The outer surface has a groove and includes a field coil disposed adjacent the at least one pole, the field coil having start and end leads. A slip ring is fixedly coupled to the start and end leads and a rotor shaft on which the field coil, the at least one pole and the slip ring are fixed. Moreover, the start and end leads are positioned within the groove and are retained in the groove by a locking feature formed in the outer surface of the at least one pole.

Abstract: An alternator rotor assembly 30 is provided, including a rear pole piece 34 having a rear pole base portion 58 and a plurality of rear pole finger portions 60 each having a rear pole fingertip 62. The plurality of rear pole finger portions 60 are positioned to form a plurality of rear pole finger gaps 64. The alternator rotor assembly 30 further includes a front pole piece 32 having a front pole base portion 50 and a plurality of front pole finger portions 52 each having a front pole fingertip 54. The plurality of front pole finger portions 52 are positioned to form a plurality of front pole finger gaps 56. The rear pole piece 34 and the front pole piece 32 are assembled such that the rear pole finger portions 60 are positioned within the front pole finger gaps 56 and the front pole finger portions 52 are positioned within the rear pole finger gaps 64. The alternator rotor assembly 30 further includes a plurality of link elements 70.

Abstract: A rotor assembly for an alternator includes an electrical wire defining an excitation winding. A first pole piece and a second pole piece each have a generally circular body defining an axis of rotation and an outer radial periphery. A plurality of pole fingers are spaced radially about and extend axially from the outer radial periphery of each pole piece parallel to the axis of rotation. Each pole piece includes a plurality of mounting surfaces spaced radially about the outer radial periphery between the pole fingers. A plurality of permanent magnets are positioned on the mounting surfaces. A plurality of covers include tabs extending therefrom and are adapted to substantially encase one of the permanent magnets. The mounting surfaces of the first and second pole pieces include ribs which are adapted to engage the tabs to secure the covers to the mounting surfaces.

Abstract: A modular unitized differential for drive axles of motor vehicles includes a barrel-shaped differential case and a bowl-shaped ring gear. The ring gear is adapted to be selectively positioned relative to the differential case for fastening in a specific position in accordance with the needed gear spacing. The arrangement allows to accommodate different gear ratios between the ring gear and input gear.

Abstract: A breather assembly (100) for a vehicular drive axle (10). The breather assembly includes a body member (102) having a vertically extending drainback tube portion (114) and a horizontally extending connecting portion (120), and a curved formed hose member (104) to minimize leakage of lubricant (S) from the drive axle axle housing (26) and ingestion of exterior water into the housing.