Abstract: A housing for a rotary electric machine having stacked laminations forming a stator core includes a first portion forming a slip fit with a first series of the stacked laminations. A second portion forms an interference fit with a second series of the stacked laminations.

Abstract: A rotor stack for connection to a shaft of a rotary electric machine includes a series of platters each centered about a centerline and including an opening for receiving the shaft such that the platters are stacked along the shaft. Passages extend through the platter and are arranged about the centerline. Permanent magnets are positioned in the passages. Hubs associated with the platters mechanically connect each of the platters to the shaft.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Conductors extend around the teeth and through the slots. The conductors are electrically connected to one another to form phases. A cooling device is provided in at least one winding slot. The cooling device includes an outer tube and an inner tube provided in the outer tube such that cooling fluid flows in a first axial direction within the inner tube and a second axial direction opposite the first axial direction within the outer tube.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Conductors extend around the teeth and through the slots. The conductors are electrically connected to one another to form phases. Cooling devices are provided in the slots. Each cooling device is fluidly connected to an inlet tube for supplying cooling fluid to the cooling device and an outlet tube for removing cooling fluid from the cooling device. A manifold includes a first cooling channel fluidly connected to each inlet tube and a second cooling channel fluidly connected to each outlet tube such that all the cooling devices in the machine are fluidly connected in parallel.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Winding coils extend around the teeth and through the slots. The winding coils are electrically connected to one another to form phases. At least one of the winding coils has a first portion extending through first and second slots of the slots and including first end turns extending between the first and second slots over an axial end surface of the teeth. A second portion extends through the first and second slots and includes second end turns extending between the first and second slots over the axial end surface of the teeth. The first and second portions are connected in series at a third end turn spaced closer to the axial end surface than either the first or second end turns.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Conductors extend around the teeth and through the slots. The conductors are electrically connected to one another to form phases. Cooling devices are provided in the slots. Each cooling device is fluidly connected to an inlet tube for supplying cooling fluid to the cooling device and an outlet tube for removing cooling fluid from the cooling device. A manifold includes a first cooling channel fluidly connected to each inlet tube and a second cooling channel fluidly connected to each outlet tube such that all the cooling devices in the machine are fluidly connected in parallel.

Abstract: One example includes a rotary electric machine. The device includes at least one sensor. Each of the at least one sensor can be configured to provide a sensor signal in a first data format, the sensor signal providing an indication of a respective one of a plurality of operational characteristics of the rotary electric machine. The device also includes a programmable interface configured to receive the sensor signal from each of the at least one sensor and to translate the first data format associated with each of the at least one sensor into a second data format associated with a respective type of sensor corresponding to the respective at least one sensor and to provide at least one output signal in the second data format. Each of the at least one output signal can correspond to at least one of the operational characteristics.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Conductors extend around the teeth and through the slots. The conductors are electrically connected to one another to form phases. A cooling device is provided in at least one winding slot. The cooling device includes an outer tube and an inner tube provided in the outer tube such that cooling fluid flows in a first axial direction within the inner tube and a second axial direction opposite the first axial direction within the outer tube.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Winding coils extend around the teeth and through the slots. The winding coils are electrically connected to one another to form phases. At least one of the winding coils has a first portion extending through first and second slots of the slots and including first end turns extending between the first and second slots over an axial end surface of the teeth. A second portion extends through the first and second slots and includes second end turns extending between the first and second slots over the axial end surface of the teeth. The first and second portions are connected in series at a third end turn spaced closer to the axial end surface than either the first or second end turns.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Conductors extend around the teeth and through the slots. The conductors are electrically connected to one another to form phases. A cooling device is provided in at least one winding slot. The cooling device includes an outer tube and an inner tube provided in the outer tube such that cooling fluid flows in a first axial direction within the inner tube and a second axial direction opposite the first axial direction within the outer tube.

Abstract: A wedge for securing a bearing and a bearing sleeve to an end bell of a rotating electric machine includes an annular base extending about a centerline and having an inner surface defining an opening through the base for receiving the bearing and the bearing sleeve. The base includes opposing first and second ends spaced circumferentially from one another by a gap for allowing relative movement therebetween during securing of the bearing and the bearing sleeve to the end bell.

Abstract: A method for securing metallic first and second parts together includes positioning filler metal along an interface between the first and second parts. The first and second parts are inserted into a fixture such that at least one of the first and second parts engages the fixture. The fixture is heated with at least one electrical heating element to heat the filler metal by thermal conduction above a melting point of the filler metal and form metallurgical bonds between the filler metal and the first and second parts. The melted filler metal is cooled to join the first and second parts together.

Abstract: A housing for a rotary electric machine having stacked laminations forming a stator core includes a first portion forming a slip fit with a first series of the stacked laminations. A second portion forms an interference fit with a second series of the stacked laminations.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Conductors extend around the teeth and through the slots. The conductors are electrically connected to one another to form phases. Cooling devices are provided in the slots. Each cooling device is fluidly connected to an inlet tube for supplying cooling fluid to the cooling device and an outlet tube for removing cooling fluid from the cooling device. A manifold includes a first cooling channel fluidly connected to each inlet tube and a second cooling channel fluidly connected to each outlet tube such that all the cooling devices in the machine are fluidly connected in parallel.

Abstract: A rotor stack for connection to a shaft of a rotary electric machine includes a series of platters each centered about a centerline and including an opening for receiving the shaft such that the platters are stacked along the shaft. Passages extend through the platter and are arranged about the centerline. Permanent magnets are positioned in the passages. Hubs associated with the platters mechanically connect each of the platters to the shaft.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Conductors extend around the teeth and through the slots. The conductors are electrically connected to one another to form phases. A cooling device is provided in at least one winding slot. The cooling device includes an outer tube and an inner tube provided in the outer tube such that cooling fluid flows in a first axial direction within the inner tube and a second axial direction opposite the first axial direction within the outer tube.

Abstract: A rotary electric machine includes a stator extending along an axis and having teeth arranged about the axis. The teeth are circumferentially spaced apart by slots. Winding coils extend around the teeth and through the slots. The winding coils are electrically connected to one another to form phases. At least one of the winding coils has a first portion extending through first and second slots of the slots and including first end turns extending between the first and second slots over an axial end surface of the teeth. A second portion extends through the first and second slots and includes second end turns extending between the first and second slots over the axial end surface of the teeth. The first and second portions are connected in series at a third end turn spaced closer to the axial end surface than either the first or second end turns.

Abstract: A wedge for securing a bearing and a bearing sleeve to an end bell of a rotating electric machine includes an annular base extending about a centerline and having an inner surface defining an opening through the base for receiving the bearing and the bearing sleeve. The base includes opposing first and second ends spaced circumferentially from one another by a gap for allowing relative movement therebetween during securing of the bearing and the bearing sleeve to the end bell.

Abstract: A method for securing metallic first and second parts together includes positioning filler metal along an interface between the first and second parts. The first and second parts are inserted into a fixture such that at least one of the first and second parts engages the fixture. The fixture is heated with at least one electrical heating element to heat the filler metal by thermal conduction above a melting point of the filler metal and form metallurgical bonds between the filler metal and the first and second parts. The melted filler metal is cooled to join the first and second parts together.