Abstract: A method for diagnosing a fault in an electrical component using a diagnostic system having a plurality of sensors. The method includes positioning the electrical component in a predetermined position adjacent the diagnostic system and at a predetermined orientation with respect to the diagnostic system. The method also includes causing a predetermined level of electrical current to flow to the electrical component, the stationary sensors sensing electrical discharge emitted by the electrical component at an area of the fault, and the tangible computerized controller receiving sensor data from the sensors. The method further includes the tangible computerized controller executing the computer-readable instructions to process the sensor data to generate test information including a location of the electrical component at which the fault is occurring in at least two dimensions.

Abstract: A method for surge testing a bar-wound stator includes electrically connecting a conductive lead of a test system to a corresponding welded hair pin in each of the layers mid-way through the stator windings. A calibrated voltage surge is applied via the conductive leads into the windings of the stator at the welded hair pins. The method includes measuring a voltage drop between turns of the windings after applying the calibrated voltage surge, recording the measured voltage drop in memory of the test system, and executing a control event with respect to the stator when the measured voltage drop is more than a calibrated threshold voltage drop. A system for surge testing the bar-wound stator includes a test device having a capacitor for storing the calibrated surge voltage and a pin set that is electrically connected to the test device. The pin set includes the conductive wires and leads.

Abstract: A method of evaluating an electrically conductive wire segment having an insulated intermediate portion and non-insulated ends includes passing the insulated portion of the wire segment through an electrically conductive brush. According to the method, an electrical potential is established on the brush by a power source. The method also includes determining a value of electrical current that is conducted through the wire segment by the brush when the potential is established on the brush. The method additionally includes comparing the value of electrical current conducted through the wire segment with a predetermined current value to thereby evaluate the wire segment. A system for evaluating an electrically conductive wire segment is also disclosed.

Abstract: A stator for an electric motor includes first and second rows of conductors arranged concentrically around an axis inside a steel core. Each conductor includes a linking end. The stator also includes a first dielectric shim ring arranged between the two rows of conductors. Each conductor of the first row is bent in either a clockwise or a counter-clockwise direction relative to the axis and each conductor of the second row is bent in the opposite direction. The linking end of each conductor of the first row is attached to the linking end of an adjacent conductor of the second row after the conductors are bent. The first shim ring separates the first and second rows of conductors when the conductors are being bent, and is also at least partially disposed between the first and second rows of conductors when the linking ends are being attached.

Abstract: A method for surge testing a bar-wound stator includes electrically connecting a conductive lead of a test system to a corresponding welded hair pin in each of the layers mid-way through the stator windings. A calibrated voltage surge is applied via the conductive leads into the windings of the stator at the welded hair pins. The method includes measuring a voltage drop between turns of the windings after applying the calibrated voltage surge, recording the measured voltage drop in memory of the test system, and executing a control event with respect to the stator when the measured voltage drop is more than a calibrated threshold voltage drop. A system for surge testing the bar-wound stator includes a test device having a capacitor for storing the calibrated surge voltage and a pin set that is electrically connected to the test device. The pin set includes the conductive wires and leads.

Abstract: A method and system for non-destructive evaluation of one or more welds of a stator includes activating the stator welds using an electrical current; recording radiometric thermal images of the welds over time; and analyzing a temperature-time profile of a weld to qualify the weld by one or more of estimating the size of the weld, determining if the temperature of the activated weld has exceeded a predetermined temperature at a predetermined time, or comparing the temperature-time profile of the weld to a reference. The stator may be configured as a bar wound stator. A mask may be applied to the stator to reduce reflections or emissions from non-weld thermal sources.

Abstract: A stator for an electric motor includes first and second rows of conductors arranged concentrically around an axis inside a steel core. Each conductor includes a linking end. The stator also includes a first dielectric shim ring arranged between the two rows of conductors. Each conductor of the first row is bent in either a clockwise or a counter-clockwise direction relative to the axis and each conductor of the second row is bent in the opposite direction. The linking end of each conductor of the first row is attached to the linking end of an adjacent conductor of the second row after the conductors are bent. The first shim ring separates the first and second rows of conductors when the conductors are being bent, and is also at least partially disposed between the first and second rows of conductors when the linking ends are being attached.

Abstract: A method for diagnosing a fault in an electrical component using a diagnostic system having a plurality of sensors. The method includes positioning the electrical component in a predetermined position adjacent the diagnostic system and at a predetermined orientation with respect to the diagnostic system. The method also includes causing a predetermined level of electrical current to flow to the electrical component, the stationary sensors sensing electrical discharge emitted by the electrical component at an area of the fault, and the tangible computerized controller receiving sensor data from the sensors. The method further includes the tangible computerized controller executing the computer-readable instructions to process the sensor data to generate test information including a location of the electrical component at which the fault is occurring in at least two dimensions.

Abstract: A method of evaluating an electrically conductive wire segment having an insulated intermediate portion and non-insulated ends includes passing the insulated portion of the wire segment through an electrically conductive brush. According to the method, an electrical potential is established on the brush by a power source. The method also includes determining a value of electrical current that is conducted through the wire segment by the brush when the potential is established on the brush. The method additionally includes comparing the value of electrical current conducted through the wire segment with a predetermined current value to thereby evaluate the wire segment. A system for evaluating an electrically conductive wire segment is also disclosed.