Abstract: Embodiments of the present invention are directed to a generator for connecting to a predefined load, where the generator is designed and constructed to meet one or more requirements of the predefined load. In specific embodiments the one or more requirements include providing a minimum output voltage while starting the predefined load at or above ambient temperature and providing an output voltage that does not exceed an upper voltage limit while being driven at full speed without any load current at or below ambient temperatures, while maintaining high efficiency under a specified full load running condition and keeping the overall cost and size of the generator low.

Abstract: Embodiments of the present invention are directed to a generator for connecting to a predefined load, where the generator is designed and constructed to meet one or more requirements of the predefined load. In specific embodiments the one or more requirements include providing a minimum output voltage while starting the predefined load at or above ambient temperature and providing an output voltage that does not exceed an upper voltage limit while being driven at full speed without any load current at or below ambient temperatures, while maintaining high efficiency under a specified full load running condition and keeping the overall cost and size of the generator low.

Abstract: Embodiments of the present invention are directed to a generator for connecting to a predefined load, where the generator is designed and constructed to meet one or more requirements of the predefined load. In specific embodiments the one or more requirements include providing a minimum output voltage while starting the predefined load at or above ambient temperature and providing an output voltage that does not exceed an upper voltage limit while being driven at full speed without any load current at or below ambient temperatures, while maintaining high efficiency under a specified full load running condition and keeping the overall cost and size of the generator low.

Abstract: A system for providing operating or charging current supply in different modes of operation includes an electric machine including a rotor and a stator having stator windings, at least one charge storage device, such as a battery, and an inverter disposed between the charge storage device terminals and the electric machine. A contact arrangement modifies electrical interconnections between phases of the inverter and the stator windings. In a supply mode, the electrical interconnections are controlled so that each inverter phase is electrically interconnected with a stator winding set having windings separated from each other by stator windings in other winding sets for driving the rotor of the electrical machine. In a charge mode, however, these interconnections are controlled so that each inverter phase is electrically interconnected with a stator winding set having windings directly adjacent to each other and are not separated from each other.

Abstract: In a process of producing a stator forming part of a rotary motor arrangement, a multiplicity of laminations are joined together to produce a first stack of laminations defining teeth, slots between adjacent teeth, and a yoke section connecting the teeth together. Coil elements are then mounted on the teeth so that the coil elements are disposed in the slots between the adjacent teeth, and a second stack of laminations is fitted onto an inner diameter of the first stack of laminations and fixed in place to function as tooth tips. At least part of the second lamination stack is then bored out or otherwise removed to dispose of all but a thin layer of the second stack of laminations bridging adjacent teeth defined by the first stack of laminations. A rotary motor stator produced by such a process is also described.

Abstract: The stator of a fluid cooled electric machine, such as a motor, a generator, or a motor/generator assembly, includes an annular stator core including inwardly projecting teeth and external grooves in an outer surface of the core that are radially aligned with the teeth. Electrically conductive windings are mounted on the inwardly projecting teeth, and a pipe assembly for coolant has a pipe formed into a serpentine shape. The pipe includes axially extending pipe portions received in the external stator core grooves, and end turns interconnecting adjacent pairs of the axially extending pipe portions. Heat conduction elements are secured to the end turns of the coolant pipe, and a housing surrounding the outer surface of the stator core retains the axially extending pipe portions within the external grooves.

Abstract: A stator arrangement for a balanced multiple voltage device operable as an electric motor, a generator, or a motor-generator includes a plurality of arc sectors configured so as to surround a rotor of the device. Each of the arc sectors includes a set of stator windings with at least one winding in each set. Those windings in pairs of the arc sectors located at diametrically opposed locations of the stator arrangement are concurrently energized and deenergized in order to eliminate load imbalance on the device.

Abstract: A rotor arrangement with decreased fluid flow impedance and improved rotary motor cooling is mountable on a shaft for rotation relative to the stator of a rotary motor arrangement The rotor arrangement has a plurality of laminations joined together to form a multilayer laminated rotor with a plurality of magnet receptacles. Each of the laminations has a solid central section surrounding an opening within which the shaft is receivable, spokes extending substantially radially outwardly from said solid central section, ribs interposed between adjacent spokes, and bridges interconnecting the spokes and ribs. At least some of the bridges are inset from an outer diameter of the lamination toward the solid central section to decrease fluid flow impedance and improve rotary motor cooling.

Abstract: In a process of producing a stator forming part of a rotary motor arrangement, a multiplicity of laminations are joined together to produce a first stack of laminations defining teeth, slots between adjacent teeth, and a yoke section connecting the teeth together. Coil elements are then mounted on the teeth so that the coil elements are disposed in the slots between the adjacent teeth, and a second stack of laminations is fitted onto an inner diameter of the first stack of laminations and fixed in place to function as tooth tips. At least part of the second lamination stack is then bored out or otherwise removed to dispose of all but a thin layer of the second stack of laminations bridging adjacent teeth defined by the first stack of laminations. A rotary motor stator produced by such a process is also described.

Abstract: The present invention provides a highly optimized motor design enabling an increase in torque compared to a similarly sized motor of traditional design. Additionally, the present invention enables motors that provide smooth, ripple free, operation at low speeds. These advances are provided through disclosure of slot/pole ratios that provide the stated benefits.

Abstract: A swing arm bracket assembly includes a shaft having a plurality of journals. One end of the shaft connects to a motor drive shaft. Each journal of the shaft has a bearing thereon and is of approximately the same axial length as the bearing. A support member is provided which connects on one end to a machine and on the other end connects to the motor. The support member also rotatably engages at least one of the bearings on the shaft. A swing arm is provided having an arm portion and a cylindrical sleeve portion extending axially through the support member. The cylindrical sleeve portion rotatably engages at least one of the bearings on the shaft.

Abstract: In an electric motor having a plurality of magnets bonded to a rotor hub, a composite sleeve is disposed over the rotor hub and magnets. The composite sleeve may be wound directly upon the rotor hub, or the composite sleeve may be wound upon a mandrel and slid over the rotor hub.

Abstract: In an electric motor having a plurality of magnets bonded to a rotor hub, a composite sleeve is disposed over the rotor hub and magnets. The composite sleeve may be wound directly upon the rotor hub, or the composite sleeve may be wound upon a mandrel and slid over the rotor hub.

Abstract: A brush holder assembly providing longer brush life and easy brush replacement is disclosed. The assembly uses a removeable spring bracket to extend a double coil constant force extension spring straddling a brush. The bracket, straddling the spring and brush, is inserted into a brush holder, whereupon it slideably engages the coils of the extension spring, causing it to extend. The bracket is removeable from the holder so that the extension spring and brush can be removed to replace a worn or broken brush.