Abstract: A phase separator for an electric machine includes a first insulator and a second insulator. The first and second insulators each include a leg portion and an endturn portion connected to the leg portion. The endturn portion is asymmetric with respect to an axis defined by the leg portion such that the second insulator can be inverted and disposed in an overlapping arrangement for electrically insulating endturn portions of adjacent phase windings.

Abstract: An electric machine includes a stator disposed about an axis in register with the rotor. The stator has a plurality of slots parallel to the axis. A plurality of windings with generally rectangular cross sections is provided with each winding having a first portion disposed radially inward of a second portion relative to the axis. At least two of the plurality of windings are at least partially inserted into each of the plurality of slots. The plurality of generally rectangular windings in each of the plurality of slots is configured to reduce resistive loss within the stator.

Abstract: A stator for a generator includes a core having a back iron that is annular in shape and poles that extend inward from the back iron, a hoop having an annular shape that is radially inward from the back iron, and a plurality of winding supports surrounding the poles. Each winding support includes a tooth extending radially inward from the hoop and surrounding a corresponding pole with the tooth having a first end adjacent to the hoop and a second end radially inward from the first end and a first channel on a first axial side of the tooth extending from the second end to the first end. The stator also includes a plurality of windings with each winding wrapped around a corresponding tooth so that each winding is spaced from the tooth at the first channel.

Abstract: A phase separator for an electric machine includes a first insulator and a second insulator. The first and second insulators each include a leg portion and an endturn portion connected to the leg portion. The endturn portion is asymmetric with respect to an axis defined by the leg portion such that the second insulator can be inverted and disposed in an overlapping arrangement for electrically insulating endturn portions of adjacent phase windings.

Abstract: A generator comprises a rotor to be driven for rotation adjacent a stator. The stator includes laminated core teeth having circumferentially intermediate slots and a conductor received within the slots. The conductor has an outer copper layer and an inner aluminum core. A stator is also disclosed.

Abstract: A wedge for an electrical machine core includes a hollow wedge body including a wedge wall extending in an axial direction. The wedge wall separates an interior hollow space of the wedge body from a space exterior to the wedge body. A phase change material can be housed within the interior hollow space of the wedge for regulating heat transfer through the wedge. An electrical machine includes a wound rotor including an electrical steel core and a plurality of wedges mounted to the electrical steel core with electrical machine windings retained between each wedge and the core body. Each of the wedges includes a hollow wedge body as described above.

Abstract: An insulating phase separator is used in an electric machine to separate phase windings in a stator assembly. The insulating phase separator includes first and second endturn portions and first and second leg portions. The first and second endturn portions each have a curved outer surface and a tabbed portion located opposite the curved outer surface. The first and second leg portions extend between the first and second endturn portions and are integral with the first and second endturn portions.

Abstract: An insulating phase separator is used in an electric machine to separate phase windings in a stator assembly. The insulating phase separator includes first and second endturn portions and first and second leg portions. The first and second endturn portions each have a curved outer surface and a tabbed portion located opposite the curved outer surface. The first and second leg portions extend between the first and second endturn portions and are integral with the first and second endturn portions.

Abstract: A method of installing the terminal block assembly onto a generator includes the step of providing a terminal block with multiple terminal studs. Protrusions that are integral with the terminal block are aligned with corresponding bores in a generator housing. The terminal block is mounted on the generator housing with the protrusions received in the bores. A terminal lead assembly is inserted through the protrusion, and a terminal pad of the terminal lead assembly is arranged over the terminal stud. A terminal lug is fastened to the terminal stud. A terminal cover is secured to the terminal block over the terminal with a boss of the terminal block received in a corresponding recess of the terminal cover.

Abstract: An electric machine includes a stator disposed about an axis in register with the rotor. The stator has a plurality of slots parallel to the axis. A plurality of windings with generally rectangular cross sections is provided with each winding having a first portion disposed radially inward of a second portion relative to the axis. At least two of the plurality of windings are at least partially inserted into each of the plurality of slots. The plurality of generally rectangular windings in each of the plurality of slots is configured to reduce resistive loss within the stator.

Abstract: An example electric machine includes a stator disposed about an axis having a plurality of slots. The electric machine also includes a plurality of windings each having a first portion and a second portion. At least two of the plurality of windings are at least partially disposed within each of the plurality of slots. At least one of the first portion or second portion of at least one of the plurality of windings of each slot includes a first exposed end with a surface having a plurality of grooves, the surface in contact with a second exposed end of at least one other winding of the same slot. The first exposed end and second exposed end form a joint between the plurality of windings. A braze material is dispersed in a plurality of grooves disposed between the first exposed end and the second exposed end.

Abstract: An electric machine includes a stator disposed about an axis in register with the rotor. The stator has a plurality of slots parallel to the axis. A plurality of windings with generally rectangular cross sections is provided with each winding having a first portion disposed radially inward of a second portion relative to the axis. At least two of the plurality of windings are at least partially inserted into each of the plurality of slots. The plurality of generally rectangular windings in each of the plurality of slots is configured to reduce resistive loss within the stator.

Abstract: A method of installing the terminal block assembly onto a generator includes the step of providing a terminal block with multiple terminal studs. Protrusions that are integral with the terminal block are aligned with corresponding bores in a generator housing. The terminal block is mounted on the generator housing with the protrusions received in the bores. A terminal lead assembly is inserted through the protrusion, and a terminal pad of the terminal lead assembly is arranged over the terminal stud. A terminal lug is fastened to the terminal stud. A terminal cover is secured to the terminal block over the terminal with a boss of the terminal block received in a corresponding recess of the terminal cover.

Abstract: A coating apparatus includes a coating transfer roll that transfers a coating material from a coating material reservoir to a work piece. The coating material reservoir is formed between the coating transfer roll, a flexible blade and reservoir wall members. The flexible blade includes a first section that is fixed to a support. A second section of the flexible blade extends along a length of the coating transfer roll and is rotatable about the first section. An actuator selectively applies a pressure on the flexible blade during a coating operation to deflect the flexible blade and control a thickness of the coating material applied to the work piece.

Abstract: A method of installing the terminal block assembly onto a generator includes the step of providing a terminal block with multiple terminal studs. Protrusions that are integral with the terminal block are aligned with corresponding bores in a generator housing. The terminal block is mounted on the generator housing with the protrusions received in the bores. A terminal lead assembly is inserted through the protrusion, and a terminal pad of the terminal lead assembly is arranged over the terminal stud. A terminal lug is fastened to the terminal stud. A terminal cover is secured to the terminal block over the terminal with a boss of the terminal block received in a corresponding recess of the terminal cover.

Abstract: A terminal block assembly for a generator includes a terminal block having a base with a first and second transverse surfaces adjoining one another. Spaced apart protrusions extend from the first and second surfaces to provide spaced apart terminal areas overlapping the first and second surface. The terminal areas are configured to receive a cable lug. A terminal stud is provided in each terminal area and extends from the second surface. The first surface is without terminal studs. A cable lug secured to the terminal stud is arranged in the terminal area.

Abstract: An example electric machine includes a stator disposed about an axis having a plurality of slots. The electric machine also includes a plurality of windings each having a first portion and a second portion. At least two of the plurality of windings are at least partially disposed within each of the plurality of slots. At least one of the first portion or second portion of at least one of the plurality of windings of each slot includes a first exposed end with a surface having a plurality of grooves, the surface in contact with a second exposed end of at least one other winding of the same slot. The first exposed end and second exposed end form a joint between the plurality of windings. A braze material is dispersed in a plurality of grooves disposed between the first exposed end and the second exposed end.

Abstract: An electric machine includes a stator disposed about an axis in register with the rotor. The stator has a plurality of slots parallel to the axis. A plurality of windings with generally rectangular cross sections is provided with each winding having a first portion disposed radially inward of a second portion relative to the axis. At least two of the plurality of windings are at least partially inserted into each of the plurality of slots. The plurality of generally rectangular windings in each of the plurality of slots is configured to reduce resistive loss within the stator.

Abstract: A gas-tight electrical connection comprises a conductive substrate with at least one socket for receiving an associated wire, at least one slot in the conductive substrate that penetrates each socket and at least one SMA force ring that slides over the conductive substrate near each slot to clamp the electrical connection when heated to its austenitic state.