Abstract: A method for manufacturing a polymeric electrical machine includes manufacturing a stator including a laminated stator core and a plurality of windings including winding overhangs; applying a surface treatment to the stator core constructed to reduce defects at an interface between a polymeric material and the stator core and enhance adherence between the polymeric material and the stator core; mounting the stator onto a mandrel; inserting the stator into an electrical machine housing mold; molding an electrical machine housing including a stator band with an integral non-drive end endplate, including overmolding the stator and winding overhangs within the stator band; molding a drive end endplate, including forming polymeric ribs in the drive end endplate and overmolding a metallic structure into the endplate, the metallic structure enhancing mechanical stiffness of the endplate; installing a rotor assembly into the electrical machine housing; and installing the endplate onto the electrical machine housing.

Abstract: A drive system is provided for propelling a ship through water. The drive system has two propellers. The propellers are coaxial so that one propeller engages the incoming water first, and the other propeller engages the water after it passes through the first propeller. The drive system has a stator that causes a first rotor to rotate. The first rotor is connected to, the first propeller to cause the first propeller to rotate. The first rotor also causes a second rotor to rotate. The second rotor is connected to the second propeller to cause the second propeller to rotate.

Abstract: An electrical machine includes a stator including a plurality of stator windings; and a rotor in magnetic cooperation with the stator. The rotor includes a plurality of cooling passages extending therethrough, each cooling passage including an inlet for receiving oil and an outlet for discharging the oil. The electrical machine includes a rotating oil distribution member coupled to the rotor, the oil distribution member including a radially inward portion and a radially outward portion, the radially outward portion being disposed adjacent to the inlets of the plurality of cooling passages. A stationary oil delivery nozzle is constructed to discharge oil toward the radially inward portion of the oil distribution member. The oil distribution member is constructed to receive the oil discharged by the oil delivery nozzle, and to direct the oil to the inlets of the cooling passages to cool the rotor.

Abstract: An electrical machine comprises a polymeric housing having a stator band, the polymeric housing formed by a polymeric material and constructed to house components of the electrical machine, structurally support the electrical machine and react torque loads generated by the electrical machine; a stator overmolded into and partially encapsulated by the stator band, the stator including a laminated stator core and a plurality of stator windings; a rotor in magnetic communication with the stator; a first endplate integral with the polymeric housing; and a second endplate, the second endplate being a polymeric endplate, the second endplate including a plurality of ribs and a metallic structure, wherein the electrical machine is constructed as an industrial electrical machine.

Abstract: A cable tie is provided with a wedge disposed within a passage extending through a head. The wedge is compressed within the passage when tension is applied to the strap. As a result, the wedge compresses the strap against an inner surface of the passage to restrain the strap.

Abstract: An electrical machine comprises a polymeric housing formed by a polymeric material and constructed to house components of the electrical machine, structurally support the electrical machine and react torque loads generated by the electrical machine; a stator overmolded into and partially encapsulated by the polymeric housing, the stator including a laminated stator core and a plurality of stator windings, the stator windings including a winding overhang extending from the laminated stator core; a rotor in magnetic communication with the stator; and a cooling channel disposed within the polymeric material forming the housing and encapsulated by the polymeric material and positioned adjacent to the laminated stator core, wherein the cooling channel is constructed to pass a fluid for cooling the electrical machine.

Abstract: A drive system is provided for propelling a ship through water. The drive system has two propellers. The propellers are coaxial so that one propeller engages the incoming water first, and the other propeller engages the water after it passes through the first propeller. The drive system has a stator that causes a first rotor to rotate. The first rotor is connected to, the first propeller to cause the first propeller to rotate. The first rotor also causes a second rotor to rotate. The second rotor is connected to the second propeller to cause the second propeller to rotate.

Abstract: A rotor is provided for an electric motor. The rotor shaft is located within a central opening of the rotor core. The central opening is sized larger than the rotor shaft such that a circumferential gap exists between the rotor core and the rotor shaft while the shaft is located by protrusions in the central opening of the rotor core. The circumferential gap is filled with a resin.

Abstract: An electrical machine comprises a polymeric housing formed by a polymeric material and constructed to house components of the electrical machine, structurally support the electrical machine and react torque loads generated by the electrical machine; a stator overmolded into and partially encapsulated by the polymeric housing, the stator including a laminated stator core and a plurality of stator windings, the stator windings including a winding overhang extending from the laminated stator core; a rotor in magnetic communication with the stator; and a cooling channel disposed within the polymeric material forming the housing and encapsulated by the polymeric material and positioned adjacent to the laminated stator core, wherein the cooling channel is constructed to pass a fluid for cooling the electrical machine.

Abstract: An electrical machine comprises a polymeric housing having a stator band, the polymeric housing formed by a polymeric material and constructed to house components of the electrical machine, structurally support the electrical machine and react torque loads generated by the electrical machine; a stator overmolded into and partially encapsulated by the stator band, the stator including a laminated stator core and a plurality of stator windings; a rotor in magnetic communication with the stator; a first endplate integral with the polymeric housing; and a second endplate, the second endplate being a polymeric endplate, the second endplate including a plurality of ribs and a metallic structure, wherein the electrical machine is constructed as an industrial electrical machine.

Abstract: A method for manufacturing a polymeric electrical machine includes manufacturing a stator including a laminated stator core and a plurality of windings including winding overhangs; applying a surface treatment to the stator core constructed to reduce defects at an interface between a polymeric material and the stator core and enhance adherence between the polymeric material and the stator core; mounting the stator onto a mandrel; inserting the stator into an electrical machine housing mold; molding an electrical machine housing including a stator band with an integral non-drive end endplate, including overmolding the stator and winding overhangs within the stator band; molding a drive end endplate, including forming polymeric ribs in the drive end endplate and overmolding a metallic structure into the endplate, the metallic structure enhancing mechanical stiffness of the endplate; installing a rotor assembly into the electrical machine housing; and installing the endplate onto the electrical machine housing.

Abstract: An electrical machine includes a stator including a plurality of stator windings; and a rotor in magnetic cooperation with the stator. The rotor includes a plurality of cooling passages extending therethrough, each cooling passage including an inlet for receiving oil and an outlet for discharging the oil. The electrical machine includes a rotating oil distribution member coupled to the rotor, the oil distribution member including a radially inward portion and a radially outward portion, the radially outward portion being disposed adjacent to the inlets of the plurality of cooling passages. A stationary oil delivery nozzle is constructed to discharge oil toward the radially inward portion of the oil distribution member. The oil distribution member is constructed to receive the oil discharged by the oil delivery nozzle, and to direct the oil to the inlets of the cooling passages to cool the rotor.

Abstract: A rotor is provided for an electric motor. The rotor shaft is located within a central opening of the rotor core. The central opening is sized larger than the rotor shaft such that a circumferential gap exists between the rotor core and the rotor shaft while the shaft is located by protrusions in the central opening of the rotor core. The circumferential gap is filled with a resin.

Abstract: A cable tie is provided with a wedge disposed within a passage extending through a head. The wedge is compressed within the passage when tension is applied to the strap. As a result, the wedge compresses the strap against an inner surface of the passage to restrain the strap.