Patents by Inventor John S. Agapiou
John S. Agapiou has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 12206285Abstract: 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.Type: GrantFiled: February 27, 2023Date of Patent: January 21, 2025Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Qigui Wang, John S. Agapiou, Liang Wang, Lei Hao, Daniel J. Wilson, Steven L Burkholder
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Patent number: 12184131Abstract: 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.Type: GrantFiled: February 25, 2022Date of Patent: December 31, 2024Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Mark A. Smith, Ante Tony Lausic, John S. Agapiou
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Patent number: 12136207Abstract: 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.Type: GrantFiled: March 9, 2022Date of Patent: November 5, 2024Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: John S. Agapiou, Sean Robert Wagner
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Patent number: 12121960Abstract: A casting die includes a first ingate defining a first annular chamber and a second ingate defining a second annular chamber and spaced from the first ingate. The die includes a first end ring gate concentric with the first ingate and defining a first end ring chamber in fluid communication with the first annular chamber, and a second end ring gate concentric with the second ingate and defining a second end ring chamber in fluid communication with the second annular chamber. The die includes runners interconnecting the first and second end ring gates. Each of the runners defines a conductor bar channel in fluid communication with the first and second end ring chambers. The die includes an overflow gate disposed between the first and second ingates, wherein the overflow gate defines an annular overflow chamber in fluid communication with the conductor.Type: GrantFiled: April 19, 2024Date of Patent: October 22, 2024Assignee: GM Global Technology Operations LLCInventors: Qigui Wang, John S. Agapiou, Liang Wang, Paul J. Boone
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Patent number: 12126225Abstract: A method of inspecting a stator stack includes disposing the stator stack on a support surface of an inspection system, and performing a depth measurement of a stator slot. The depth measurement includes rotating the stator slot along a first direction to a plurality of first orientations, taking a first image at each of the first orientations, and measuring a depth based on at least one of the first images. The method includes performing a width measurement of the stator slot, which includes rotating the stator slot along a second direction to a plurality of second orientations, taking a second image at each of the second orientations, and measuring a width based on at least one of the second images. The method further includes inspecting edges of the stator slot in the at least one of the first images to detect a potential deviation.Type: GrantFiled: March 9, 2022Date of Patent: October 22, 2024Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: John S. Agapiou, Sean Robert Wagner
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Publication number: 20240291332Abstract: 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.Type: ApplicationFiled: February 27, 2023Publication date: August 29, 2024Inventors: Qigui Wang, John S. Agapiou, Liang Wang, Lei Hao, Daniel J. Wilson, Steven L. Burkholder
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Publication number: 20240257996Abstract: A method of making an electric conductor having a conductive skin layer. The method comprises providing a conductive member having a first width and a conductive layer disposed thereon for conductivity. The conductive layer has a second width to define a width ratio of the first width to the second width of 4:1 to 200:1. The conductive layer has greater conductivity than the conductive member. The method comprises disposing the conductive layer about the conductive member to define a conductive layered member and pressing the conductive layered member for mechanical contact to define a pressed layered member. The method comprises thermally treating the pressed layered member for diffusion between the conductive layer and the conductive member defining a diffused layered member. The method further comprises cooling the diffused layered member for diffusion bonding free of an intermetallic phase between the conductive layer and the conductive member.Type: ApplicationFiled: January 30, 2023Publication date: August 1, 2024Inventors: Qigui Wang, John S. Agapiou, Liang Wang, Lei Hao
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Publication number: 20240250570Abstract: An electric motor includes a stator and a rotor rotatable relative to the stator and having an air gap between the rotor and the stator, wherein at least one of the stator and the rotor include a plurality of windings formed from ultra-conducting copper foil.Type: ApplicationFiled: May 4, 2023Publication date: July 25, 2024Inventors: Lei HAO, Qigui WANG, John S. AGAPIOU, Thomas W. NEHL, Xiaohui DU
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Publication number: 20240250590Abstract: A method of making a conductor includes folding/stacking/rolling an ultra-conducting copper foil into a multiple layer folded/stacked/rolled ultra-conducting copper foil. Cladding the multiple layer folded/stacked/rolled ultra-conducting coper foil with one of copper and aluminum into a cladded folded/stacked/rolled ultra-conducting copper foil and plastically deforming the cladded folded/stacked/rolled ultra-conducting copper foil into one of a cladded ultra-conducting copper wire, bar, and cable.Type: ApplicationFiled: January 25, 2023Publication date: July 25, 2024Inventors: John S. AGAPIOU, Qigui WANG, Lei HAO
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Publication number: 20240217027Abstract: A system for welding together tips of different wires arranged about a motor stator. A scanner control module is configured to operate a three-dimensional scanner to scan the tips of the different wires and measure alignment of the tips in X, Y, and Z directions of a coordinate plane. A system control module is configured to compare the measured alignment of the tips to a predetermined alignment range, and configured to identify a weld schedule for each of the tips that fall within the predetermined alignment range. A laser welder control module is configured to operate a laser welder to weld together only the tips aligned within the predetermined alignment range in accordance with the weld schedule identified by the system control module.Type: ApplicationFiled: December 28, 2022Publication date: July 4, 2024Inventors: Chen ZHOU, Wuhua Yang, John S. Agapiou, Terebara Hughes, Thiagarajan Chidambareswaran
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Publication number: 20240125840Abstract: 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.Type: ApplicationFiled: October 12, 2022Publication date: April 18, 2024Inventors: John S. AGAPIOU, Ronald M. LESPERANCE
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Publication number: 20240055961Abstract: 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.Type: ApplicationFiled: August 12, 2022Publication date: February 15, 2024Inventors: John S. AGAPIOU, Timothy M. WILSON
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Publication number: 20240014699Abstract: 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.Type: ApplicationFiled: July 26, 2022Publication date: January 11, 2024Inventors: John S. Agapiou, Jian Yao, Zhen Gao, SeungHwan Keum
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Publication number: 20230291284Abstract: A method of inspecting a stator stack includes disposing the stator stack on a support surface of an inspection system, and performing a depth measurement of a stator slot. The depth measurement includes rotating the stator slot along a first direction to a plurality of first orientations, taking a first image at each of the first orientations, and measuring a depth based on at least one of the first images. The method includes performing a width measurement of the stator slot, which includes rotating the stator slot along a second direction to a plurality of second orientations, taking a second image at each of the second orientations, and measuring a width based on at least one of the second images. The method further includes inspecting edges of the stator slot in the at least one of the first images to detect a potential deviation.Type: ApplicationFiled: March 9, 2022Publication date: September 14, 2023Inventors: John S. Agapiou, Sean Robert Wagner
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Publication number: 20230289953Abstract: 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.Type: ApplicationFiled: March 9, 2022Publication date: September 14, 2023Inventors: John S. Agapiou, Sean Robert Wagner
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Publication number: 20230275494Abstract: 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.Type: ApplicationFiled: February 25, 2022Publication date: August 31, 2023Inventors: Mark A. Smith, Ante Tony Lausic, John S. Agapiou
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Patent number: 11675012Abstract: Methods and systems for detecting partial discharge in a stator for an electric motor are provided. An exemplary method includes applying a high voltage AC sinewave input signal to the stator and energizing at least one winding therein. The method includes sensing a first resulting load signal occurring in the stator with a first device and filtering the first resulting load signal to form a first high frequency signal indicating any partial discharge (PD) voltage occurring in the stator. The method also includes sensing a second resulting load signal occurring in the stator with a second device and filtering the second resulting load signal to form a second high frequency signal indicating any partial discharge voltage occurring in the stator. Further, the method includes processing the first and second high frequency signals to form a processed signal indicating whether partial discharge occurred.Type: GrantFiled: September 27, 2021Date of Patent: June 13, 2023Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Ronald M Lesperance, John S Agapiou
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Publication number: 20230115294Abstract: Methods and systems for detecting partial discharge in a stator for an electric motor are provided. An exemplary method includes applying a high voltage AC sinewave input signal to the stator and energizing at least one winding therein. The method includes sensing a first resulting load signal occurring in the stator with a first device and filtering the first resulting load signal to form a first high frequency signal indicating any partial discharge (PD) voltage occurring in the stator. The method also includes sensing a second resulting load signal occurring in the stator with a second device and filtering the second resulting load signal to form a second high frequency signal indicating any partial discharge voltage occurring in the stator. Further, the method includes processing the first and second high frequency signals to form a processed signal indicating whether partial discharge occurred.Type: ApplicationFiled: September 27, 2021Publication date: April 13, 2023Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Ronald M. Lesperance, John S. Agapiou
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Patent number: 11552541Abstract: An induction motor includes a stator and a rotor. The stator is configured to generate a rotating magnetic field. The rotor is disposed inside the stator, separated from the stator by an air gap, and is configured to rotate around an axis in response to the rotating magnetic field. The rotor includes a rotor core, multiple end rings, and multiple collars. The end rings are attached at opposite ends of the rotor core. Each end ring has one of multiple regions disposed outside the air gap. Each region has an outer surface. The collars are attached in a prestressed condition around the outer surface of each region. The prestressed condition is configured to maintain a compressive stress in the end rings at a maximum-designed rotational speed of the rotor.Type: GrantFiled: January 18, 2021Date of Patent: January 10, 2023Assignee: GM Global Technology Operations LLCInventors: John S. Agapiou, Edwin H. Chang, Yew Sum Leong
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Patent number: 11545880Abstract: Stator cores and methods for fabricating stator cores are provided. An exemplary stator core includes a stack of laminations. Each lamination in the stack of laminations comprises a yoke and a plurality of tooth segments fixed to the yoke.Type: GrantFiled: October 22, 2020Date of Patent: January 3, 2023Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: John S. Agapiou, James G. Schroth