Abstract: A system and method for inspecting and laser welding a workpiece at an area of interest on the workpiece includes a first camera configured to view the area of interest along a first line of sight, a second camera configured to view the area of interest along a second line of sight different from the first line of sight, a laser welding scan head configured to laser weld the workpiece at the area of interest, and a control system configured to receive input from each of the first and second cameras, determine one or more alignment measurements based on the received input, and select a weld schedule from a plurality of weld schedules based on the one or more alignment measurements.

Abstract: A rotor stack assembly includes multiple plates each including multiple elongated slots each oriented radially outward from a longitudinal central axis of each plate toward an outer perimeter wall of the plate. Multiple openings are each positioned proximate to one of the slots and directed outwardly through the outer perimeter wall. Multiple runners individually extend through the plate and individually open into one of opposed ends of each of the slots. Multiple bars of a conductive material are each extended through aligned ones of the slots of each of the multiple plates.

Abstract: Apparatus and methods are provided for manufacturing a rotor. The rotor has a core with an open center, conductive bars extending across the core and conductive end rings at ends of the core. A mandrel has a body that extends through the open center and a head that extends over and engage the first end of the core around the open center. A central cap couples with the body, extends over and engages the second end of the core around the open center. An end cap covers the central cap and engages the core around the open center. The end cap defines at least part of a cavity around the conductive bars for receiving molten metal.

Abstract: A partial discharge calibration standard apparatus may include a first and second rigid members defining respective first and second facing surfaces. An electrically insulating material may be disposed between the facing surfaces. The apparatus may further include a pressure member maintaining the rigid members together, thereby fixing the first and second facing surfaces in a substantially parallel spaced relation across the insulating material such that a partial discharge threshold magnitude for an electrical potential difference between the first and second facing surfaces is determined.

Abstract: A rotor stack assembly includes multiple plates each including multiple elongated slots each oriented radially outward from a longitudinal central axis of each plate toward an outer perimeter wall of the plate. Multiple openings are each positioned proximate to one of the slots and directed outwardly through the outer perimeter wall. Multiple runners individually extend through the plate and individually open into one of opposed ends of each of the slots. Multiple bars of a conductive material are each extended through aligned ones of the slots of each of the multiple plates.

Abstract: An electric motor includes a stator assembly and a rotor configured to rotate within the stator assembly about an axis. The stator assembly includes a stator case having a channel and a laminate steel core having a retention feature aligned with the channel of the stator case. The stator case is fixed to the laminate steel core via displacement of material of the stator case at the channel toward the laminate steel core to capture the retention feature. An electro-mechanical drive-unit employing the above-described electric motor and a method of generating a stator assembly for such an electric motor are also contemplated.

Abstract: A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Abstract: A method for manufacturing a stator includes the steps of: (1) providing a stator core module having a first stator fixture disposed on a first side of the stator core module, the first stator fixture is configured to support a first set of stator core junction portions in a fixed position; (2) providing a first crown module having a set of first crown junction portions and a first crown fixture to support the first set of first crown junction portions; (3) aligning the first stator fixture with the first crown fixture so that the first set of stator core junction portions are aligned with the first crown junction portions; and (4) joining the first set of stator core junction portions with the first crown junction portions.

Abstract: A rotor for an induction motor includes a first shorting end ring, a second shorting end ring, and a plurality of conductor bars. Each conductor bar has a first end and a second end and is coated with an electrically conductive material. The first end of each conductor bar is in electrical and mechanical contact with the first shorting end ring, and the second end of each conductor bar is in electrical and mechanical contact with the second shorting end ring. The conductive material is disposed between each conductor bar and the respective shorting end rings.

Abstract: A tool insert includes first, second, and third teeth arranged on a surface of the tool insert. The first tooth is arranged at a proximal end of the tool insert surface and has an angled leading end and a first tooth height. The second tooth is spaced from the first tooth by a first distance along the surface of the tool insert and has a second tooth height greater than the first tooth height. The third tooth is spaced from the second tooth by a second distance along the surface of the tool insert and has an extending angled portion. The first tooth forms a first groove in a bore surface. The second tooth increases the depth of the first groove. The third tooth provides at least one micro-scratch to one of the first groove and the bore surface.

Abstract: A method for manufacturing an induction rotor includes placing a lamination stack into a fixture in which the first end of the lamination stack is rotated in an opposite rotational direction from the second end of the lamination stack to skew the conduction bars to an angle ?. Vertical members are fixed to an outer perimeter of each of the plurality of laminates of the lamination stack. Hoop members are fixed to each of the plurality of vertical members and an outer edge of each of the plurality of conduction bars. A conduction ring is fixed on each of the ends of the lamination stack. An outer perimeter of the lamination stack is machined to remove the plurality of vertical members and the plurality of hoop members from the lamination stack.

Abstract: A rotor for an electromagnetic machine and a method of assembling the rotor are provided. In one embodiment, the rotor includes a lamination stack disposed about a rotational axis a plurality of conductor bars disposed within corresponding slots formed in the lamination stack and extending beyond the longitudinal ends of the lamination stack. End rings are positioned at either end of the lamination stack and define a plurality of openings configured to receive the ends of the conductor bars. Each end ring includes separate inner and outer concentric rings. The inner and outer rings define radially outer and inner surfaces configured to about one another and each of the concentric rings defines a portion of each conductor bar opening in the end ring.

Abstract: An arc welding/brazing process is disclosed that is useful to join together a first copper piece and a second copper piece without damaging more heat-sensitive materials that may be located nearby is disclosed. The arc welding/brazing process includes using a non-consumable electrode wire, which electrically communicates with a weld control in a straight polarity orientation, to strike an arc across a gap established between a leading tip end of the electrode wire and the first copper piece. The current that flows through the arc when the arc is established heats the first copper piece such that the first copper piece becomes joined to a second copper piece. The joint between the first copper piece and the second copper piece may be an autogenous weld joint or a braze joint.

Abstract: A rotor for an induction motor includes a first shorting end ring, a second shorting end ring, and a plurality of conductor bars. Each conductor bar has a first end and a second end and is coated with an electrically conductive material. The first end of each conductor bar is in electrical and mechanical contact with the first shorting end ring, and the second end of each conductor bar is in electrical and mechanical contact with the second shorting end ring. The conductive material is disposed between each conductor bar and the respective shorting end rings.

Abstract: A lamination pack for a motor and method of forming the lamination pack is provided. The method includes inserting a plurality of conductor bars into a plurality of rotor slots defined by a lamination stack such that opposing bar ends of the conductor bars extend from opposing end faces of the lamination stack, skewing the lamination stack and the conductor bars to a skew angle relative to a rotation axis of the lamination stack, and subsequently bending the bar ends of the conductor bars in opposing radial directions to a locking angle greater than the skew angle, to lock each of the conductor bars in its respective rotor slot. The bent bar ends exert a compressive axial locking force on the lamination stack to prevent axial and radial movement of the laminations in the lamination stack and to prevent axial movement of the conductor bars relative to the lamination stack.

Abstract: A system for offsetting a CNC machining process includes transferring compensation variables through registers in fixed G-code programming of the CNC machine and offsetting the CNC machine without altering fixed G-code programming. Global compensation variables are applied to all feature programs of the CNC machining process, and local compensation variables are applied to only individual features or groups of features. The machine shifts position in response to the compensation variables.

Abstract: An electric motor includes a stator assembly and a rotor configured to rotate within the stator assembly about an axis. The stator assembly includes a stator case having a channel and a laminate steel core having a retention feature aligned with the channel of the stator case. The stator case is fixed to the laminate steel core via displacement of material of the stator case at the channel toward the laminate steel core to capture the retention feature. An electro-mechanical drive-unit employing the above-described electric motor and a method of generating a stator assembly for such an electric motor are also contemplated.

Abstract: A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

Abstract: A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

Abstract: A tool insert includes first, second, and third teeth arranged on a surface of the tool insert. The first tooth is arranged at a proximal end of the tool insert surface and has an angled leading end and a first tooth height. The second tooth is spaced from the first tooth by a first distance along the surface of the tool insert and has a second tooth height greater than the first tooth height. The third tooth is spaced from the second tooth by a second distance along the surface of the tool insert and has an extending angled portion. The first tooth forms a first groove in a bore surface. The second tooth increases the depth of the first groove. The third tooth provides at least one micro-scratch to one of the first groove and the bore surface.