Abstract: An alternator assembly 10 having a pair of housing members 11, 12 which cooperatively contain a stator 24, rotor 18, and bearing 29. The housing member 12 includes an integrally formed bearing sleeve member 40 which receives the bearing 29 and allows the rotor 18 to rotate within the assembly 10.

Abstract: An electrical machine comprising a rotor (26) mounted on a shaft (29) for rotation therewith and defining an axis of rotation, and a stator (54) disposed coaxially with and in opposition to the rotor (26). The electrical machine further comprises a housing (22, 24) enclosing the stator (54) and the rotor (26), the housing (22, 24) having a first axial end with a wall with an inner surface and an outer surface and a second axial end with a wall with an inner surface and an outer surface. The electrical machine also includes a first cooling tube (80′) having a first end and a second end and an embedded portion thereof embedded between the first inner surface and the first outer surface of end wall (81). A second cooling tube (82′) has a first end and a second end and an embedded portion thereof embedded between said inner surface and said outer surface of the wall (83) of the second axial end.

Abstract: A brush holder assembly (12) for a rotating electrical machine such as an alternator (10) has a cavity (56) therein. The cavity (56) is defined by a first wall (60), a second wall (62), a third wall (64), and a fourth wall (66). The cavity (56) is sized to receive a brush (42) of the rotating electrical machine. One of the walls (60), (62), (64), and (66) comprise a first drafted surface. A positioning rib (70) is provided on at least the drafted surface to position the brush (42) substantially parallel to the longitudinal axis (58) of the cavity (56).

Abstract: An electrical machine such as an alternator (10) has a first housing (14) and a second housing (16) with a stator core assembly (18) therein. The stator core assembly has a plurality of windings (44) that are positioned within laminations (46). The windings have a first set of end turns (48), a second set of end turns (50), and winding ends 52. A respective first end cap (54) and a second end cap (56) are placed over respective end turns (48) (50). Potting material (58) is placed between the first end cap (54) and the first set of end turns (48) and the second end cap (56) and the second set of end turns (50). A stud assembly (60) having a stud housing (62) and a plurality of studs (64) is coupled to the first end cap. A bushing (68) is coupled to the studs (64) so that winding ends (52) may be coupled to a flat surface (70) thereof. The bushings (68) are also used to from an electrical connection between the rectifier bridge (36) and the stator core (42).

Abstract: An alternator assembly 10 having a pair of housing members 11, 12 which cooperatively contain a stator 24, rotor 18, and bearing 29. The housing member 12 includes an integrally formed bearing sleeve member 40 which receives the bearing 29 and allows the rotor 18 to rotate within the assembly 10.