Abstract: An insulation inspection system includes: a support for a part being inspected; brushes including respective sets of conductive bristles, where the sets of conductive bristles brush against respective insulated portions of the part; at least one motor configured to at least one of i) move the part relative to the brushes, and ii) one or more of the brushes relative to the part; and a control module configured to i) control the at least one motor to follow a movement profile, and ii) during movement of at least one of the part and the one or more of the brushes, detect a defect in insulative material of the part due to a short circuit between one or more of the conductive bristles of the brushes and an exposed conductive element of the part in a location of the defect.

Abstract: A method of installing a stator and a motor housing includes inserting a stator into a motor housing, the motor housing having a shaft bore and a plurality first bolt holes end of the state are having a bore opening and a plurality of second bolt holes. A centering fixture is inserted into the shaft bore of the housing and into the bore opening, the centering fixture includes a first centering device received into the shaft bore and a second centering device received into the bore opening of the stator. A locating plate is secured to the motor housing and engaged with the centering fixture. The first centering devices actuated for centering the centering fixture relative to the shaft and the second centering device is actuated for centering the state are relative to the shaft board. The plurality of bolts are tightened to secure the stator to the motor housing.

Abstract: An insulation inspection system includes: a set of input terminals; a brush; a circuit connected to the set of input terminals, the brush, and a part being inspected, where the circuit includes at least one pair of resistors and a capacitor; and a control module configured to detect when a short circuit exists between a conductive element of the part and one or more conductive bristles due to insulative material missing on the part and as a result the one or more conductive bristles of the brush contacting the conductive element of the part.

Abstract: A composite wire bundle for a stator winding, a stator including a composite wire bundle, and a method of forming a composite wire bundle. The composite wire bundle includes a plurality of copper wires, wherein each of the plurality of copper wires include a first surface. The composite wire bundle also includes a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface. Further, the composite wire bundle includes a fluoropolymer matrix formed around the second surfaces and a jacket encapsulating the fluoropolymer matrix.

Abstract: A method of forming a stack of laminates for a stator includes stamping in sequence a plurality of annular stator laminates from a continuous sheet of metal. The annular stator laminates each including an interior surface with a plurality of winding teeth and an exterior surface with a plurality of circumferentially spaced radially protruding ears wherein the plurality of circumferentially spaced radially protruding ears of each adjacently formed annular stator laminate is circumferentially offset from the circumferentially spaced radially protruding ears of immediately adjacent annular stator laminates. Clocking each of the annular stator laminates a predetermined angular rotation relative to an adjacent annular stator and stacking the annular stator laminates with the circumferentially spaced radially protruding ears aligned within the stack.

Abstract: An electric machine including a stator and a rotor. The rotor is configured to rotate within the stator and includes: a core; a first end ring at a first end of the core and a second end ring at a second end of the core; conductors extending across the core that electrically connect the first end ring and the second end ring; and a first reinforcing ring that is cast within the first end ring and a second reinforcing ring that is cast within the second end ring.

Abstract: A rotatable stator sensor device includes a stator support plate configured to support a steel stator having multiple teeth, a rotary table electrically isolated from the stator support plate, and at least two sensors on the rotary table. The at least two sensors are located within an inner circumference of the steel stator, each of the at least two sensors including two sensor legs, and a distance between the two sensor legs corresponds to a distance between two of the multiple teeth of the steel stator. The device includes a sensor rotation control module configured to rotate the at least two sensors between a first position aligned with a first set of the multiple teeth of the steel stator, and a second position aligned with a second set of the multiple teeth of the steel stator.

Abstract: A testing system includes an AC signal generator configured to selectively generate a sinusoidal signal including a plurality of cycles. A dielectric strength and partial discharge tester sequentially performs dielectric strength and partial discharge testing of a stator of an electric machine using the sinusoidal signal. Another testing system includes an impulse signal generator configured to selectively generate an impulse signal including a plurality of cycles. A surge and partial discharge tester for sequentially performing surge and partial discharge testing of a stator of an electric machine using the impulse signal.

Abstract: An insulation inspection system includes: a support for a part being inspected; brushes including respective sets of conductive bristles, where the sets of conductive bristles brush against respective insulated portions of the part; at least one motor configured to at least one of i) move the part relative to the brushes, and ii) one or more of the brushes relative to the part; and a control module configured to i) control the at least one motor to follow a movement profile, and ii) during movement of at least one of the part and the one or more of the brushes, detect a defect in insulative material of the part due to a short circuit between one or more of the conductive bristles of the brushes and an exposed conductive element of the part in a location of the defect.

Abstract: An insulation inspection system includes: conductive brushes arranged to brush insulated portions of a part being inspected; voltage and current balancing circuits connected to the conductive brushes, where each of the voltage and current balancing circuits is configured to detect a short circuit between one or more bristles of the conductive brushes and an exposed conductive element of the part; and a control module configured to detect a defect in insulative material of the part in response to the detected short circuit.

Abstract: An insulation inspection system includes: a set of input terminals; a brush; a circuit connected to the set of input terminals, the brush, and a part being inspected, where the circuit includes at least one pair of resistors and a capacitor; and a control module configured to detect when a short circuit exists between a conductive element of the part and one or more conductive bristles due to insulative material missing on the part and as a result the one or more conductive bristles of the brush contacting the conductive element of the part.

Abstract: A composite wire bundle for a stator winding, a stator including a composite wire bundle, and a method of forming a composite wire bundle. The composite wire bundle includes a plurality of copper wires, wherein each of the plurality of copper wires include a first surface. The composite wire bundle also includes a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface. Further, the composite wire bundle includes a fluoropolymer matrix formed around the second surfaces and a jacket encapsulating the fluoropolymer matrix.

Abstract: An induction rotor assembly includes a laminated stack, conductor bars, a first end ring, and a second end ring. The laminated stack includes a body with a first end, an opposing second end, and an outer circumferential surface extending from the first end to the second end along a longitudinal axis. The conductor bars are disposed within grooves in the outer circumferential surface. Each conductor bar includes a first conductor end and a second conductor end extending beyond the ends of the laminated stack. The first conductor end and the second conductor end of each of the conductor bars includes a serrated surface having serrations. The first end ring and second end ring interlock with the serrated surface of the conductor ends. The conductor bars extend between the first end ring and the second end ring.

Abstract: An eccentricity detection system includes: a vibration eccentricity module configured to determine a vibration eccentricity of the electric motor based on vibration of the electric motor measured during operation of the motor; an inductance eccentricity module configured to determine an inductance eccentricity of the electric motor based on an incremental inductance curve of the electric motor; and a fault module configured to indicate whether the electric motor includes an eccentricity fault based on both (a) the vibration eccentricity of the electric motor and (b) the inductance eccentricity of the electric motor.

Abstract: An axial flux electric motor includes a housing including an inner surface and a stator fixedly mounted in the housing. The stator includes a plurality of stator segments each supporting a winding, an inner support member defining a central passage, and an outer annular member constraining the plurality of stator segments. The outer annular member includes an outer surface portion abutting the inner surface of the housing. A thermal connection system is disposed between the outer surface portion of the outer annular member and the inner surface. The thermal connection system transfers heat from the stator into the housing.

Abstract: A rotatable stator sensor device includes a stator support plate configured to support a steel stator having multiple teeth, a rotary table electrically isolated from the stator support plate, and at least two sensors on the rotary table. The at least two sensors are located within an inner circumference of the steel stator, each of the at least two sensors including two sensor legs, and a distance between the two sensor legs corresponds to a distance between two of the multiple teeth of the steel stator. The device includes a sensor rotation control module configured to rotate the at least two sensors between a first position aligned with a first set of the multiple teeth of the steel stator, and a second position aligned with a second set of the multiple teeth of the steel stator.

Abstract: A method of forming a stack of laminates for a stator includes stamping in sequence a plurality of annular stator laminates from a continuous sheet of metal. The annular stator laminates each including an interior surface with a plurality of winding teeth and an exterior surface with a plurality of circumferentially spaced radially protruding ears wherein the plurality of circumferentially spaced radially protruding ears of each adjacently formed annular stator laminate is circumferentially offset from the circumferentially spaced radially protruding ears of immediately adjacent annular stator laminates. Clocking each of the annular stator laminates a predetermined angular rotation relative to an adjacent annular stator and stacking the annular stator laminates with the circumferentially spaced radially protruding ears aligned within the stack.

Abstract: An induction rotor assembly having conductive bars is provided. The assembly comprises a lamination stack comprising a body having a first end and second ends to define a longitudinal axis. The body has an outer circumferential portion extending from the first end to the second end. The outer portion has a plurality of walls defining open slots formed from the first end through the second end. The assembly further comprises a first ring disposed on the first end and a second ring disposed on the second end. The assembly further comprises a plurality of conductive bars extending between the first and second rings. Each conductive bar is disposed in one of the slots such that the respective conductive bar is in contact with the lamination stack and connects the first and second rings. Each bar comprises an inner portion and a conductive outer skin disposed about the inner portion.

Abstract: An interlocking tool for a for forming stator end turns includes a first member including a first base having a first surface. A first ring extends from the first surface and a second ring extends from the first surface radially outwardly of the first ring. The second ring is spaced from the first ring by a first gap. A second member includes a second base having a first surface portion. A first ring element extends from the first surface portion and a second ring element extends from the first surface portion radially inwardly of the first ring element. The second ring element is spaced from the first ring element by a second gap. The second ring is positioned in the second gap, and the second ring element is positioned in the first gap. The first member is rotatable relative to the second member.

Abstract: A system for inspecting a stator stack includes a rotary table, an imaging device configured to take a plurality of images of a portion of the stator stack including a stator slot, an illuminator configured to apply illumination through the stator slot, and an alignment and monitoring system configured to monitor and orient the stator slot relative to the imaging axis. The alignment and monitoring system includes a tilting system configured to move the stator slot between a plurality of orientations relative to an imaging axis, the imaging device configured to take a respective image at each of the plurality of orientations, a controller configured to control the tilting system based on one or more measurements of each image, and a processor configured to analyze each image and select an orientation of the stator slot as an optimal orientation for inspection of the stator slot.