Patents by Inventor Edward L. Kaiser
Edward L. Kaiser has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20210234447Abstract: An electric machine includes a machine rotor circumscribed by a machine stator, and having a rotor shaft, rotor stack, and end cap which rotate about an axis. The end cap includes lobes equal in number to a number of pole pairs of the machine rotor. A position sensor assembly has a predetermined alignment with the machine rotor and stator. The sensor assembly includes a sensor rotor formed by the lobes and a sensor stator having a printed circuit board with conductive sine and cosine traces. Machine rotor rotation causes the sensor assembly to output an unmodulated sine and cosine signals to a controller, which then calculates a calibrated reference angle. A magnetic axis of an electrical phase of the machine is aligned with and bisects a peak of the sine trace. A direct axis of the machine rotor aligns with an edge of a lobe.Type: ApplicationFiled: January 28, 2020Publication date: July 29, 2021Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Suresh Gopalakrishnan, Chandra S. Namuduri, Alexandru Rajala, Thomas W. Nehl, Xiaohui Du, Edward L. Kaiser
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Patent number: 11056943Abstract: A stator assembly includes a plurality of stator slots having multiple respective slot layers and a plurality of hairpins. The plurality of hairpins have a respective first leg positioned in one of the multiple respective slot layers and a respective second leg positioned in another of the multiple respective slot layers. A first set of n adjacent slots of the plurality of stator slots is configured to accommodate the plurality of hairpins carrying a current in a first phase, n being an integer. The plurality of hairpins is configured in respective conductor layers (L1, L2 . . . ) having a plurality of respective turn locations defining n respective turn positions. The plurality of hairpins is configured to occupy the n respective turn positions an equal number of times such that the respective conductor layers (L1, L2 . . . ) are electrically balanced.Type: GrantFiled: July 3, 2018Date of Patent: July 6, 2021Assignee: GM Global Technology Operations LLCInventors: Khwaja M. Rahman, Xiaohui Du, Edward L. Kaiser
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Publication number: 20200185982Abstract: A stator for an electromagnetic machine includes a first lamination stack defining a first cavity therein and having a central longitudinal axis. The first lamination stack includes a first plurality of mounting ears disposed opposite the first cavity and each spaced apart from one another about the central longitudinal axis. The stator further includes a second lamination stack abutting the first lamination stack and defining a second cavity therein aligned with the first cavity along the central longitudinal axis. The second lamination stack includes a second plurality of mounting ears disposed opposite the second cavity and each spaced apart from the first plurality of mounting ears and from one another about the central longitudinal axis. An electromagnetic machine including the stator and a device including the electromagnetic machine are also described.Type: ApplicationFiled: December 10, 2018Publication date: June 11, 2020Applicant: GM Global Technology Operations LLCInventors: Pavan Kumar Patruni, Song He, Edward L. Kaiser, Mithun Sunny
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Patent number: 10680472Abstract: A stator for an electromagnetic machine includes a first lamination stack defining a first cavity therein and having a central longitudinal axis. The first lamination stack includes a first plurality of mounting ears disposed opposite the first cavity and each spaced apart from one another about the central longitudinal axis. The stator further includes a second lamination stack abutting the first lamination stack and defining a second cavity therein aligned with the first cavity along the central longitudinal axis. The second lamination stack includes a second plurality of mounting ears disposed opposite the second cavity and each spaced apart from the first plurality of mounting ears and from one another about the central longitudinal axis. An electromagnetic machine including the stator and a device including the electromagnetic machine are also described.Type: GrantFiled: December 10, 2018Date of Patent: June 9, 2020Assignee: GM Global Technology Operations LLCInventors: Pavan Kumar Patruni, Song He, Edward L. Kaiser, Mithun Sunny
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Patent number: 10658889Abstract: An electromagnetic machine includes a motor housing defining a cavity therein, and a stator disposed within the cavity. The stator has an external surface and a plurality of mounting ears each configured to receive a fastener and extending from the external surface towards the motor housing. The assembly includes a tunable insert ring disposed between the motor housing and the stator. The tunable insert ring and the stator define at least one cooling channel therebetween. The tunable insert ring encircles the external surface and includes a plurality of projections each extending towards and disposed in contact with the stator to thereby stiffen the electromagnetic machine and minimize vibration of the stator within the motor housing. A device including the electromagnetic machine is also described.Type: GrantFiled: September 12, 2018Date of Patent: May 19, 2020Assignee: GM Global Technology Operations LLCInventors: Xuan Q. Tran, Edward L. Kaiser, Song He
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Publication number: 20200083764Abstract: An electromagnetic machine includes a motor housing defining a cavity therein, and a stator disposed within the cavity. The stator has an external surface and a plurality of mounting ears each configured to receive a fastener and extending from the external surface towards the motor housing. The assembly includes a tunable insert ring disposed between the motor housing and the stator. The tunable insert ring and the stator define at least one cooling channel therebetween. The tunable insert ring encircles the external surface and includes a plurality of projections each extending towards and disposed in contact with the stator to thereby stiffen the electromagnetic machine and minimize vibration of the stator within the motor housing. A device including the electromagnetic machine is also described.Type: ApplicationFiled: September 12, 2018Publication date: March 12, 2020Applicant: GM Global Technology Operations LLCInventors: Xuan Q. Tran, Edward L. Kaiser, Song He
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Publication number: 20200014267Abstract: A stator assembly includes a plurality of stator slots having multiple respective slot layers and a plurality of hairpins. The plurality of hairpins have a respective first leg positioned in one of the multiple respective slot layers and a respective second leg positioned in another of the multiple respective slot layers. A first set of n adjacent slots of the plurality of stator slots is configured to accommodate the plurality of hairpins carrying a current in a first phase, n being an integer. The plurality of hairpins is configured in respective conductor layers (L1, L2 . . . ) having a plurality of respective turn locations defining n respective turn positions. The plurality of hairpins is configured to occupy the n respective turn positions an equal number of times such that the respective conductor layers (L1, L2 . . . ) are electrically balanced.Type: ApplicationFiled: July 3, 2018Publication date: January 9, 2020Applicant: GM Global Technology Operations LLCInventors: Khwaja M. Rahman, Xiaohui Du, Edward L. Kaiser
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Patent number: 10447108Abstract: A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.Type: GrantFiled: February 22, 2017Date of Patent: October 15, 2019Assignee: GM Global Technology Operations LLC.Inventors: Xiaohui Du, Robert T. Dawsey, Edward L. Kaiser, Paul Buchholz
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Patent number: 10340761Abstract: An electric device and a stator assembly for the electric device includes a stator core defining a plurality of slots spaced from each other. The stator assembly includes a plurality of bar conductors disposed in each of the slots and arranged to present a first winding path, a second winding path and a third winding path. A first set of the bar conductors of the first, second and third winding paths are configured to receive current in a parallel circuit arrangement. The stator assembly also includes a plurality of electrical jumpers electrically connected to a predetermined number of the bar conductors such that an amount of current flowing through the first winding path and the third winding path is substantially the same and an amount of current flowing through the second winding path is different from the amount of current flowing through the first and third winding paths.Type: GrantFiled: March 26, 2015Date of Patent: July 2, 2019Assignee: GM Global Technology Operations LLCInventors: Paul F. Turnbull, Edward L. Kaiser, Matthew D. Laba, Khwaja M. Rahman, Rolf Blissenbach
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Patent number: 10207439Abstract: An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.Type: GrantFiled: February 6, 2017Date of Patent: February 19, 2019Assignee: GM Global Technology Operations LLCInventors: Edward L. Kaiser, Amanda Luedtke, Peter J. Savagian, Sinisa Jurkovic
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Patent number: 10141810Abstract: A connection support assembly for a stator assembly can be used to secure electrical jumper wires of an electric machine. The connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip.Type: GrantFiled: February 29, 2016Date of Patent: November 27, 2018Assignee: GM Global Technology Operations LLCInventors: Edward L. Kaiser, Paul Buchholz, Xiaohui Du
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Publication number: 20180241277Abstract: A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.Type: ApplicationFiled: February 22, 2017Publication date: August 23, 2018Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Xiaohui Du, Robert T. Dawsey, Edward L. Kaiser, Paul Buchholz
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Patent number: 9847704Abstract: An improved rotor assembly configured for magnets with differing lengths, and methods and systems for manufacturing the same. The rotor assembly may be created by selectively creating first and second tabs extending into apertures of lamination sheets. The first and second tabs may be selectively removed, depending on the different magnet lengths and the specific lamination sheet, according to one of a first finishing schedule and a second finishing schedule. The lamination sheets are stacked with any remaining first and second tabs, and other features, aligned.Type: GrantFiled: November 4, 2015Date of Patent: December 19, 2017Assignee: GM Global Technology Operations LLCInventors: Edward L. Kaiser, Peter J. Savagian, Khwaja M. Rahman
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Publication number: 20170250588Abstract: A connection support assembly for a stator assembly can be used to secure electrical jumper wires of an electric machine. The connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip.Type: ApplicationFiled: February 29, 2016Publication date: August 31, 2017Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Edward L. Kaiser, Paul Buchholz, Xiaohui Du
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Patent number: 9712005Abstract: An interior permanent magnet machine includes a rotor having a plurality of slots. First and second slots are disposed in a first pole and the third and fourth slots are disposed in a second pole. A first angle is defined between respective centerlines of the first and second slots. A second angle is defined between respective centerlines of the third and fourth slots. The first angle is configured to be sufficiently different from the second angle so that torque ripple is reduced. Thus the rotor is configured such that the angular configuration of slots in a first pole is different from the angular configuration of slots in a second pole of the rotor.Type: GrantFiled: December 2, 2014Date of Patent: July 18, 2017Assignee: GM Global Technology Operations LLCInventors: Khwaja M. Rahman, Sinisa Jurkovic, Edward L. Kaiser, Peter J. Savagian
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Publication number: 20170179779Abstract: A rotor rotatable about an axis includes a plurality of magnets and a plurality of laminations stacked along the axis. The laminations have an outer surface distal from the axis and an inner surface proximal to the axis. A plurality of magnet slots are defined between the outer surface and the inner surface between an exterior barrier near the outer surface and an interior barrier near the inner surface. The magnets are disposed within the magnet slots between the exterior barrier and the interior barrier, such that a first end of the magnet is adjacent the exterior barrier and a second end of the magnet is adjacent the interior barrier. An inner retention stop extends into the magnet slots at the interior barrier, and is formed within the interior barrier nearer the outer surface.Type: ApplicationFiled: December 18, 2015Publication date: June 22, 2017Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Edward L. Kaiser, David A. Wyrembelski
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Publication number: 20170144346Abstract: An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.Type: ApplicationFiled: February 6, 2017Publication date: May 25, 2017Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Edward L. Kaiser, Amanda Luedtke, Peter J. Savagian, Sinisa Jurkovic
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Patent number: 9621001Abstract: A rotor assembly for an electric machine includes a plurality of lamination sheets. Each of the lamination sheets defines an aperture. The lamination sheets are disposed adjacent each other to define a laminated stack. The apertures are aligned with each other to define a slot extending parallel with a central axis of the laminated stack. A magnet is disposed within the slot. The lamination sheets include a group of recess lamination sheets and a tab lamination sheet. The tab lamination sheet includes a tab that extends into the slot, and into abutting engagement with the magnet to bias the magnet against a wall of the slot. The apertures of the group of recess lamination sheets include a groove portion that defines a groove. The tab of the tab lamination sheet is at least partially disposed within the groove defined by the recess lamination sheets.Type: GrantFiled: October 23, 2013Date of Patent: April 11, 2017Assignee: GM Global Technology Operations LLCInventors: Edward L. Kaiser, Paul Buchholz
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Patent number: 9601976Abstract: A method and assembly for forming a rotor include forming a rotor core having a plurality of voids and placing the formed rotor core into a die cavity. The method includes moving a plurality of support shoes to define an outer diameter of the die cavity, and injecting at least one of the plurality of voids with a magnetic slurry. At least one permanent magnet is formed from the magnetic slurry by applying pressure to the rotor core and the magnetic slurry within the die cavity and by applying a magnetic field to align the magnetic slurry. After forming the at least one permanent magnet within the rotor core, the plurality of support shoes are retracted and the rotor core removed with the at least one permanent magnet formed therein.Type: GrantFiled: April 14, 2014Date of Patent: March 21, 2017Assignee: GM Global Technology Operations LLCInventors: Edward L. Kaiser, Amanda Luedtke, Peter J. Savagian, Sinisa Jurkovic
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Patent number: 9583983Abstract: An electric motor assembly includes a housing and a stator. The housing includes an outer housing surface, an inner housing surface defining an interior housing cavity, and a plurality of housing protrusions extending from the inner housing surface. The stator is disposed in the inner housing cavity and includes an outer stator surface, an inner stator surface, and a plurality of stator protrusions extending from the outer stator surface toward the outer housing surface. The stator protrusions are configured to mate with the housing protrusions to frictionally couple the stator to the housing in order to fix the stator relative to the housing.Type: GrantFiled: May 30, 2013Date of Patent: February 28, 2017Assignee: GM Global Technology Operations LLCInventors: Timothy J. Alfermann, Edward L. Kaiser, Ryan Van Tiem