Abstract: A method of determining the accuracy and repeatability of leak testing instrumentation comprises the following steps: providing a two chamber vessel having an access port and a flow controlling reference orifice associated with each chamber and a third reference orifice communicating between the two chambers, providing a leak testing device and connecting such leak testing device first to one of such ports, pressurizing the associated chamber and, with the associated orifice open, observing and recording the pressure measured by the leak testing device under test as a function of time. The second test repeats this activity with the other chamber and the other orifice. A third test is undertaken with the third orifice open. One of the chambers is smaller and incorporates a smaller orifice and the other chamber is larger and incorporates a larger orifice thus achieving leak testing under different conditions.

Abstract: A method for diagnosing a fault in an electrical component using a diagnostic system having a plurality of sensors. The method includes positioning the electrical component in a predetermined position adjacent the diagnostic system and at a predetermined orientation with respect to the diagnostic system. The method also includes causing a predetermined level of electrical current to flow to the electrical component, the stationary sensors sensing electrical discharge emitted by the electrical component at an area of the fault, and the tangible computerized controller receiving sensor data from the sensors. The method further includes the tangible computerized controller executing the computer-readable instructions to process the sensor data to generate test information including a location of the electrical component at which the fault is occurring in at least two dimensions.

Abstract: An electrical part testing system for evaluating quality of an insulated electrical part, including a computer-controlled switching apparatus for providing an original voltage to the electrical part automatically according to a pre-established testing scheme calling for provision of voltage to each phase of the part, in turn, while grounding the other phases of the part. A high-frequency filter for receiving receive the original voltage, receiving a load voltage emanating from the electrical part in response to the part receiving the original voltage, and filtering the original voltage from the load voltage to isolate any partial-discharge voltage added to the original voltage by the electrical part while the part is being electrified by the original voltage, yielding a filtered signal. A computing device determines, based on a comparison of a peak amplitude of the partial-discharge inception voltage to a voltage threshold, the quality of the electrical part being tested.

Abstract: A seal testing apparatus includes a clamp assembly which receives, secures and rotates a piston and seal assembly, a mandrel which extends into the seal assembly and supports a guide which carries a spring biased sensing probe or tooth which is oriented along the axis of the mandrel. In another embodiment, the components are the similar except that the probe or tooth is disposed in the mandrel and extends circumferentially. In both embodiments, data from an optical, laser or acoustic sensor is analyzed to determine the integrity of the piston seal. Yet another embodiment includes an arbor which rotates the seal and an adjacent contra-rotating cylinder having a conical mirror. As the seal, arbor and cylinder rotate, light reflected off the mirror and the seal, and returned to the mirror and a sensor provide data which is again analyzed to determine the integrity of the piston seal.

Abstract: A rotor for an induction motor includes a rotor core having first and second ends and a plurality of conductor bars. Each conductor bar has a respective first end extending beyond the first end of said rotor core. Each first exposed end has a respective enclosed opening. The rotor also includes an end ring comprising a casting of material flowed between the respective first ends of the conductor bars and through the respective closed openings.

Abstract: A part transfer system includes a robotic arm, and an end effector attached to the robotic arm. The end effector includes a locating pin that is operable to engage an existing part feature of a part. The presence of the existing part feature is required for the intended use of the part, and therefore serves a function of the part other than a transfer function. The existing part feature defines a circular aperture disposed on a feature plane. The locating pin includes an engagement portion that extends along a longitudinal axis of the at least one locating pin. The engagement portion includes a diameter that is tapered along the longitudinal axis such that the engagement portion of the locating pin engages a radial inner edge of the circular aperture on the feature plane along an approximately annular contact ring disposed about a circumference of the tapered portion.

Abstract: A method for properly locating a flexible fixture on a CNC machine comprises probing a plurality of locators on a flexible fixture to determine a locator position on a coordinate system for the CNC machine. The position for each of the plurality of locators is analyzed to determine if all of the plurality of locators are within a predetermined offset limit from a nominal position. A controller is programmed with an offset compensation amount based upon the probed position for each locator when each of the plurality of locators is within the predetermined offset limit. The locator positions are adjusted if one of the probed locations is not within the predetermined offset limit. The CNC probing programs are generated by a computer language to accommodate various fixture configurations.

Abstract: A seal testing apparatus includes a clamp assembly which receives, secures and rotates a piston and seal assembly, a mandrel which extends into the seal assembly and supports a guide which carries a spring biased sensing probe or tooth which is oriented along the axis of the mandrel. In another embodiment, the components are the similar except that the probe or tooth is disposed in the mandrel and extends circumferentially. In both embodiments, data from an optical, laser or acoustic sensor is analyzed to determine the integrity of the piston seal. Yet another embodiment includes an arbor which rotates the seal and an adjacent contra-rotating cylinder having a conical mirror. As the seal, arbor and cylinder rotate, light reflected off the mirror and the seal, and returned to the mirror and a sensor provide data which is again analyzed to determine the integrity of the piston seal.

Abstract: A method of determining the accuracy and repeatability of leak testing instrumentation comprises the following steps: providing a two chamber vessel having an access port and a flow controlling reference orifice associated with each chamber and a third reference orifice communicating between the two chambers, providing a leak testing device and connecting such leak testing device first to one of such ports, pressurizing the associated chamber and, with the associated orifice open, observing and recording the pressure measured by the leak testing device under test as a function of time. The second test repeats this activity with the other chamber and the other orifice. A third test is undertaken with the third orifice open. One of the chambers is smaller and incorporates a smaller orifice and the other chamber is larger and incorporates a larger orifice thus achieving leak testing under different conditions.

Abstract: A method for calibrating a CNC machine comprises mounting a gauge to a table of the CNC machine and calibrating a probe to the gauge mounted on the CNC machine. A total deviation of the probe and an actual table center position from a nominal table center position for a coordinate system associated with the CNC machine are determined. A controller operatively connected to the CNC machine and the probe is programmed to compensate for the total deviation.

Abstract: An apparatus for joining a wire pair of a stator coil. The apparatus includes a tool having a pair of electrodes and control equipment. The control equipment is configured to control the electrodes to apply force to the wire pair to push adjacent wires of the wire pair toward each other and cause current to pass between the pair of electrodes, and so through the wire pair pushed together, at a time at which the force is being applied to the wire pair.

Abstract: A method of forming a rotor, wherein the rotor includes a plurality of conductor bars each joined to a shorting ring, includes disposing an end of each of the plurality of conductor bars within a respective one of a plurality of cavities defined by the shorting ring. The method also includes, after disposing, deforming the end of each of the conductor bars, and brazing the end of each of the conductor bars to the shorting ring to form the rotor. A rotor includes a shorting ring defining a plurality of cavities therein each having a shape, a plurality of conductor bars each having an end disposed within a respective one of the cavities and joined to the shorting ring, wherein the end is deformable to the shape, and a braze material disposed in contact with the end of each of the conductor bars within a respective one of the cavities.

Abstract: A stator for an electric motor includes a stator coil including a wire pair with respective ends that are joined with a ring. The ring is positioned around the wire pair and joined to the wire pair by a metal joining process.

Abstract: A method and system for non-destructive evaluation of one or more welds of a stator includes activating the stator welds using an electrical current; recording radiometric thermal images of the welds over time; and analyzing a temperature-time profile of a weld to qualify the weld by one or more of estimating the size of the weld, determining if the temperature of the activated weld has exceeded a predetermined temperature at a predetermined time, or comparing the temperature-time profile of the weld to a reference. The stator may be configured as a bar wound stator. A mask may be applied to the stator to reduce reflections or emissions from non-weld thermal sources.

Abstract: A method of manufacturing a rotor assembly includes placing a generally cylindrical rotor core in a die. The rotor core has axial grooves spaced about a perimeter of the rotor core. The grooves may be formed by stacked laminated disks. Material is cast around the annular rotor core in the die such that the cast material forms conductor bars that fill the grooves and first end ring portions at opposing ends of the rotor core connected with the conductor bars. Each of the first end ring portions has substantially a first axial width. The rotor core with cast conductor bars and cast first end ring portions is then removed from the die. A respective second end ring portion is welded to each of the cast first end ring portions to form end ring assemblies. Each second end ring portion has a second axial width greater than the first axial width.

Abstract: A method for diagnosing a fault in an electrical component using a diagnostic system having a plurality of sensors. The method includes positioning the electrical component in a predetermined position adjacent the diagnostic system and at a predetermined orientation with respect to the diagnostic system. The method also includes causing a predetermined level of electrical current to flow to the electrical component, the stationary sensors sensing electrical discharge emitted by the electrical component at an area of the fault, and the tangible computerized controller receiving sensor data from the sensors. The method further includes the tangible computerized controller executing the computer-readable instructions to process the sensor data to generate test information including a location of the electrical component at which the fault is occurring in at least two dimensions.

Abstract: A method of detecting a gap between a valve seat insert and a port in a cylinder head may include heating the valve seat insert and the cylinder head and generating a thermal image of the valve seat insert and the cylinder head at an interface between the valve seat insert and corresponding port in the cylinder head housing the valve seat insert. The thermal image may be evaluated to determine the magnitude of a gap between the valve seat insert and the cylinder head based on a temperature at the interface between the valve seat insert and the cylinder head.

Abstract: A method for properly locating a flexible fixture on a CNC machine comprises probing a plurality of locators on a flexible fixture to determine a locator position on a coordinate system for the CNC machine. The position for each of the plurality of locators is analyzed to determine if all of the plurality of locators are within a predetermined offset limit from a nominal position. A controller is programmed with an offset compensation amount based upon the probed position for each locator when each of the plurality of locators is within the predetermined offset limit. The locator positions are adjusted if one of the probed locations is not within the predetermined offset limit. The CNC probing programs are generated by a computer language to accommodate various fixture configurations.

Abstract: A welding apparatus for an induction motor includes a fixture operable to support a rotor and rotate the rotor about an axis of rotation of the motor, and a welding head supported adjacent the fixture and operable to weld conductor bars located about the surface of the rotor to the first shorting ring when the fixture supports the rotor. A controller controls the fixture to selectively rotate the rotor. The controller moves the welding head, the fixture, or both, so that the welding head is in a welding position, and causes the welding head to weld the conductor bars to the first shorting ring while remaining in the welding position, with the rotor rotating to create a substantially circular weld path along the first shorting ring. In some embodiments, the conductor bars are welded to both shorting rings simultaneously. A method of welding an induction motor is also provided.

Abstract: An apparatus for joining a wire pair of a stator coil. The apparatus includes a tool having a pair of electrodes and control equipment. The control equipment is configured to control the electrodes to apply force to the wire pair to push adjacent wires of the wire pair toward each other and cause current to pass between the pair of electrodes, and so through the wire pair pushed together, at a time at which the force is being applied to the wire pair.