Abstract: An electric machine including a stator, a rotor surrounded by and rotatable relative to the stator, a supply terminal assembly, and an electronic module electrically connected to the stator. The electronic module includes a terminal having at least one bonding region. An electrical buss is attached to the supply terminal assembly, and includes a first and second conductor portions each having a connection region joined to a bonding region of the terminal of the electronic module. The terminal of the electronic module is electrically connected to the supply terminal assembly by the first and second conductor portions. Also disclosed is a method for manufacturing such an electric machine.

Abstract: An alternator includes a housing body, and an electronics chassis electrically in common with output voltage (B+) of the alternator, conductively isolated from heat of the housing body, and having cooling fins. An air router intermediate the housing body and the chassis directs cooling air from air intake openings to the cooling fins. An electric machine includes a housing with air intake openings, an electronics chassis having rectifier electronics mounted thereon and having axially-extending cooling fins, and an air router secured intermediate the housing body and the electronics chassis, for routing the cooling air from the air intake openings directly to the cooling fins. An alternator includes a housing, an electronics chassis electrically in common with (B+), air intake openings, and an air router secured intermediate the housing body and the electronics chassis, the air router structured for routing air from the air intake openings directly to the electronics chassis.

Abstract: A method of cooling electronics of an alternator includes mounting the electronics onto an electrically conductive electronics chassis, and electrically connecting the electronics chassis to a positive DC (B+) output voltage terminal of the alternator, whereby the electronics chassis is electrically insulated from ground potential and thermally conductively isolated from the alternator housing. An alternator includes the housing at ground potential, the electronics chassis at B+ potential, and the mounted electronics. The electronics chassis is electrically insulated and conductively isolated from the housing. An electric machine includes the electronics chassis having an electronics mounting surface, and a convection surface, and defines an electrical bus for conducting a B+ potential. An electronics chassis assembly has an insulator secured between the housing at ground potential and the electronics chassis.

Abstract: An electric machine having a stator and a rotor operably coupled therewith. An accessory is coupled with the electric machine and an electrical device is mounted in a housing. The housing may advantageously include a polymeric shell that is overmolded on a conductive element providing communication between the electrical device and an external circuit. In some embodiments, a printed circuit board is mounted within the housing and thermally coupled with a metallic base member. In other embodiments, a second printed circuit board is provided with the first printed circuit board having a substrate with a greater thermal conductivity than the substrate of the second printed circuit board. The first printed circuit board may include a MOSFET rectifier and may take the form of a ceramic printed circuit board with the second board being an FR-4 board. The electric machine may be advantageously employed as an alternator for a vehicle.

Abstract: An electric machine including a stator, a rotor surrounded by and rotatable relative to the stator, a supply terminal assembly, and an electronic module electrically connected to the stator. The electronic module includes a terminal having at least one bonding region. An electrical buss is attached to the supply terminal assembly, and includes a first and second conductor portions each having a connection region joined to a bonding region of the terminal of the electronic module. The terminal of the electronic module is electrically connected to the supply terminal assembly by the first and second conductor portions. Also disclosed is a method for manufacturing such an electric machine.

Abstract: A method of cooling electronics of an alternator includes mounting the electronics onto an electrically conductive chassis, and electrically connecting the chassis to positive DC output voltage (B+) of the alternator, whereby the chassis is electrically insulated from ground potential and conductively isolated from heat of the housing. An alternator includes a housing at ground potential, a chassis at B+ potential, and electronics mounted to the chassis, where the chassis is electrically insulated and conductively isolated from the housing. An electric machine includes a B+ chassis having an electronics mounting surface, having a convection surface, and defining an electrical bus for conducting a B+ potential. A chassis assembly has an insulator secured between a frame at ground potential and the B+ chassis.

Abstract: An alternator includes a housing body, and an electronics chassis electrically in common with output voltage (B+) of the alternator, conductively isolated from heat of the housing body, and having cooling fins. An air router intermediate the housing body and the chassis directs cooling air from air intake openings to the cooling fins. An electric machine includes a housing with air intake openings, an electronics chassis having rectifier electronics mounted thereon and having axially-extending cooling fins, and an air router secured intermediate the housing body and the electronics chassis, for routing the cooling air from the air intake openings directly to the cooling fins. An alternator includes a housing, an electronics chassis electrically in common with (B+), air intake openings, and an air router secured intermediate the housing body and the electronics chassis, the air router structured for routing air from the air intake openings directly to the electronics chassis.

Abstract: An internal cooling fan assembly for use with a claw-pole segment of a rotor assembly is provided that maximizes air flow while providing a reduced sound signature. The fan assembly includes a base portion that contacts the claw-pole segment when the fan assembly is mounted to the claw-pole segment. The fan assembly also includes a number of blades extending from the base portion such that the blades project outward from a plane normal to the rotor. The plurality of blades have a geometry that aligns with roots of the claw-pole segment. In addition, a first blade of the number of blades is of a first configuration and a second blade of the number of blades is of a second configuration different from the first configuration.

Abstract: Methods, systems, and articles of manufacture for fastening internal cooling fans to claw-pole segments are provided. A claw-pole segment suitable for use in a rotor of an electro-mechanical machine is formed. The claw-pole segment may include a base portion, at least one claw pole projecting axially from the base in a first direction, and at least one protrusion projecting axially from the base in a second direction opposite the first direction. A fan assembly that attaches to the claw-pole segment is also formed. The fan assembly may include at least one opening for receiving the at least one protrusion, and may be formed with varying configurations to affect the frequency response of the fan. The portion of the at least one protrusion extends through and beyond the opening of the fan assembly when the fan assembly is mounted on the claw-pole segment and expands in response to an application of an axial load, to secure the fan assembly to the claw-pole segment.

Abstract: An internal cooling fan assembly for use with a claw-pole segment of a rotor assembly is provided that maximizes air flow while providing a reduced sound signature. The fan assembly includes a base portion that contacts the claw-pole segment when the fan assembly is mounted to the claw-pole segment. The fan assembly also includes a number of blades extending from the base portion such that the blades project outward from a plane normal to the rotor. The plurality of blades have a geometry that aligns with roots of the claw-pole segment. In addition, a first blade of the number of blades is of a first configuration and a second blade of the number of blades is of a second configuration different from the first configuration.

Abstract: Methods, systems, and articles of manufacture for fastening internal cooling fans to claw-pole segments are provided. A claw-pole segment suitable for use in a rotor of an electromechanical machine is formed. The claw-pole segment may include a base portion, at least one claw pole projecting axially from the base in a first direction, and at least one protrusion projecting axially from the base in a second direction opposite the first direction. A fan assembly that attaches to the claw-pole segment is also formed. The fan assembly may include at least one opening for receiving the at least one protrusion, and may be formed with varying configurations to affect the frequency response of the fan. The portion of the at least one protrusion extends through and beyond the opening of the fan assembly when the fan assembly is mounted on the claw-pole segment and expands in response to an application of an axial load, to secure the fan assembly to the claw-pole segment.

Abstract: An electronic package for an electrical machine preferably a rotary current generator includes a slip ring end (SRE) frame defining one end of a housing configured for mounting a rotor therein so as to be rotatable; a plurality of negative diodes dispersed in an angular fashion in the SRE frame acting as a negative heat sink; a plurality of positive diodes mounted on a separate electrically conductive plate located above a location of the plurality of negative diodes, the plate being configured as a positive heat sink having corresponding holes such that leads extending from each negative diode protrude directly therethrough and openings formed in the positive heat sink to engage a body of each positive diode; and a non-conductive separator fitted over a series of bosses that space the positive heat sink above a top surface defining the negative heat sink, the separator configured to electrically insulate the positive heat sink and negative heat sink from one another, wherein waste heat from the positive and

Abstract: An electronic package for an electrical machine preferably a rotary current generator includes a slip ring end (SRE) frame defining one end of a housing configured for mounting a rotor therein so as to be rotatable; a plurality of negative diodes dispersed in an angular fashion in the SRE frame acting as a negative heat sink; a plurality of positive diodes mounted on a separate electrically conductive plate located above a location of the plurality of negative diodes, the plate being configured as a positive heat sink having corresponding holes such that leads extending from each negative diode protrude directly therethrough and openings formed in the positive heat sink to engage a body of each positive diode; and a non-conductive separator fitted over a series of bosses that space the positive heat sink above a top surface defining the negative heat sink, the separator configured to electrically insulate the positive heat sink and negative heat sink from one another, wherein waste heat from the positive and