Abstract: An electric machine (40, 40?) has a stator (43) and a rotor (46) and a primary air gap (48) has secondary coils (47c, 47d) separated from the rotor (46) by a secondary air gap (49) so as to induce a slip current in the secondary coils (47c, 47d). The rotor (46, 76) has magnetic brushes (A, B, C, D) or wires (80) which couple flux in through the rotor (46) to the secondary coils (47c, 47d) without inducing a current in the rotor (46) and without coupling a stator rotational energy component to the secondary coils (47c, 47d). The machine can be operated as a motor or a generator in multi-phase or single-phase embodiments. A method of providing a slip energy controller is also disclosed.

Abstract: A method of making a squirrel cage rotor of copper material for use in AC or DC motors, includes forming a core with longitudinal slots, inserting bars of conductive material in the slots, with ends extending out of opposite ends of the core, and joining the end rings to the bars, wherein the conductive material of either the end rings or the bars is copper. Various methods of joining the end rings to the bars are disclosed including electrofriction welding, current pulse welding and brazing, transient liquid phase joining and casting. Pressure is also applied to the end rings to improve contact and reduce areas of small or uneven contact between the bar ends and the end rings. Rotors made with such methods are also disclosed.

Abstract: A method for providing additional dc inputs or outputs (49, 59) from a dc-to-ac inverter (10) for controlling motor loads (60) comprises deriving zero-sequence components (Vao, Vbo, and Vco) from the inverter (10) through additional circuit branches with power switching devices (23, 44, 46), transforming the voltage between a high voltage and a low voltage using a transformer or motor (42, 50), converting the low voltage between ac and dc using a rectifier (41, 51) or an H-bridge (61), and providing at least one low voltage dc input or output (49, 59). The transformation of the ac voltage may be either single phase or three phase. Where less than a 100% duty cycle is acceptable, a two-phase modulation of the switching signals controlling the inverter (10) reduces switching losses in the inverter (10). A plurality of circuits for carrying out the invention are also disclosed.

Abstract: A radial gap brushless electric machine (30) having a stator (31) and a rotor (32) and a main air gap (34) also has at least one stationary excitation coil (35a, 36a) separated from the rotor (32) by a secondary air gap (35e, 35f, 36e, 36f) so as to induce a secondary flux in the rotor (32) which controls a resultant flux in the main air gap (34). Permanent magnetic (PM) material (38) is disposed in spaces between the rotor pole portions (39) to inhibit the second flux from leaking from said pole portions (39) prior to reaching the main air gap (34). By selecting the direction of current in the stationary excitation coil (35a, 36a) both flux enhancement and flux weakening are provided for the main air gap (34). A method of non-diffused flux enhancement and flux weakening for a radial gap machine is also disclosed.

Abstract: This invention teaches methods of making a hermetic terminal assembly comprising the steps of: inserting temporary stops, shims and jigs on the bottom face of a terminal assembly thereby blocking assembly core open passageways; mounting the terminal assembly inside a vacuum chamber using a temporary assembly perimeter seal and flange or threaded assembly interfaces; mixing a seal admixture and hardener in a mixer conveyor to form a polymer seal material; conveying the polymer seal material into a polymer reservoir; feeding the polymer seal material from the reservoir through a polymer outlet valve and at least one polymer outlet tube into the terminal assembly core thereby filling interstitial spaces in the core adjacent to service conduits, temporary stop, and the terminal assembly casing; drying the polymer seal material at room temperature thereby hermetically sealing the core of the terminal assembly; removing the terminal assembly from the vacuum chamber, and; removing the temporary stops, shims.

Abstract: A cascaded die mounting device and method using spring contacts for die attachment, with or without metallic bonds between the contacts and the dies, is disclosed. One embodiment is for the direct refrigerant cooling of an inverter/converter carrying higher power levels than most of the low power circuits previously taught, and does not require using a heat sink.

Abstract: A method of making a squirrel cage rotor of copper material for use in AC or DC motors, includes forming a core with longitudinal slots, inserting bars of conductive material in the slots, with ends extending out of opposite ends of the core, and joining the end rings to the bars, wherein the conductive material of either the end rings or the bars is copper. Various methods of joining the end rings to the bars are disclosed including electrofriction welding, current pulse welding and brazing, transient liquid phase joining and casting. Pressure is also applied to the end rings to improve contact and reduce areas of small or uneven contact between the bar ends and the end rings. Rotors made with such methods are also disclosed.

Abstract: A multiple zone hermetic inverter/converter chamber for cooling power electronics using direct contact cooling in the liquid refrigerant zone and vapor refrigerant zone located in the hermetic container, and indirect non-contact cooling in the ambient cooling zone located in the interstitial space between the hermetic container and the thermally isolated housing. The ambient cooling zone operates at atmospheric pressure.

Abstract: A method for making a motor and auxiliary devices with a unified stator body comprises providing a piece of material (10) having an area larger than a cross section of the stator (11), removing material from the piece of material (10) to form a pattern for a cross section of a core (11) for the stator, and removing material from the piece of material (10) outside the cross section of the core of the stator (11) to allow positioning of cores (22, 23, 24) for supporting windings (25, 26, 27) of least one additional electromagnetic device, such as a transformer (62) in a dc-to-dc converter (61, 62) that provides a low. voltage dc output. An article of manufacture made according to the invention is also disclosed and apparatus made with the method and article of manufacture are also disclosed.

Abstract: A superconducting PM machine has a stator, a rotor and a stationary excitation source without the need of a ferromagnetic frame which is cryogenically cooled for operation in the superconducting state. PM material is placed between poles on the rotor to prevent leakage or diffusion of secondary flux before reaching the main air gap, or to divert PM flux where it is desired to weaken flux in the main air gap. The PM material provides hop-along capability for the machine in the event of a fault condition.

Abstract: A method for providing additional dc inputs or outputs (49, 59) from a dc-to-ac inverter (10) for controlling motor loads (60) comprises deriving zero-sequence components (Vao, Vbo, and Vco) from the inverter (10) through additional circuit branches with power switching devices (23, 44, 46), transforming the voltage between a high voltage and a low voltage using a transformer or motor (42, 50), converting the low voltage between ac and dc using a rectifier (41, 51) or an H-bridge (61), and providing at least one low voltage dc input or output (49, 59). The transformation of the ac voltage may be either single phase or three phase. Where less than a 100% duty cycle is acceptable, a two-phase modulation of the switching signals controlling the inverter (10) reduces switching losses in the inverter (10). A plurality of circuits for carrying out the invention are also disclosed.

Abstract: A method for making a motor and auxiliary devices with a unified stator body comprises providing a piece of material (10) having an area larger than a cross section of the stator (11), removing material from the piece of material (10) to form a pattern for a cross section of a core (11) for the stator, and removing material from the piece of material (10) outside the cross section of the core of the stator (11) to allow positioning of cores (22, 23, 24) for supporting windings (25, 26, 27) of least one additional electromagnetic device, such as a transformer (62) in a dc-to-dc converter (61, 62) that provides a low voltage dc output. An article of manufacture made according to the invention is also disclosed and apparatus made with the method and article of manufacture are also disclosed.

Abstract: A brushless electric machine (30) having a stator (31) and a rotor (32) and a main air gap (34), the rotor (32) having pairs of rotor pole portions (22b, 22c, 32f, 32l) disposed at least partly around the axis of rotation (32p) and facing the main air gap (24b, 24c, 34), at least one stationary winding (20b, 20c, 33b) separated from the rotor (22b, 22c, 32) by a secondary air gap (23b, 23c, 35) so as to induce a rotor-side flux in the rotor (22b, 22c, 32) which controls a resultant flux in the main air gap (24b, 24c, 34). PM material (27b, 27c) is disposed in spaces between the rotor pole portions (22b, 22c, 32f, 32l) to inhibit the rotor-side flux from leaking from said pole portions (22b, 22c, 32f, 32l) prior to reaching the main air gap (24b, 24c, 34). By selecting the direction of current in the stationary winding (20b, 20c, 33b) both flux enhancement and flux weakening are provided for the main air gap (24b, 24c, 34).

Abstract: A superconducting PM machine has a stator, a rotor and a stationary excitation source without the need of a ferromagnetic frame which is cryogenically cooled for operation in the superconducting state. PM material is placed between poles on the rotor to prevent leakage or diffusion of secondary flux before reaching the main air gap, or to divert PM flux where it is desired to weaken flux in the main air gap. The PM material provides hop-along capability for the machine in the event of a fault condition.

Abstract: A brushless electric machine (30) having a stator (31) and a rotor (32) and a main air gap (34), the rotor (32) having pairs of rotor pole portions (22b, 22c, 32f, 32l) disposed at least partly around the axis of rotation (32p) and facing the main air gap (24b, 24c, 34), at least one stationary winding (20b, 20c, 33b) separated from the rotor (22b, 22c, 32) by a secondary air gap (23b, 23c, 35) so as to induce a rotor-side flux in the rotor (22b, 22c, 32) which controls a resultant flux in the main air gap (24b, 24c, 34). PM material (27b, 27c) is disposed in spaces between the rotor pole portions (22b, 22c, 32f, 32l) to inhibit the rotor-side flux from leaking from said pole portions (22b, 22c, 32f, 32l) prior to reaching the main air gap (24b, 24c, 34). By selecting the direction of current in the stationary winding (20b, 20c, 33b) both flux enhancement and flux weakening are provided for the main air gap (24b, 24c, 34).

Abstract: An uncluttered secondary induction machine (100) includes an uncluttered rotating transformer (66) which is mounted on the same shaft as the rotor (73) of the induction machine. Current in the rotor (73) is electrically connected to current in the rotor winding (67) of the transformer, which is not electrically connected to, but is magnetically coupled to, a stator secondary winding (40). The stator secondary winding (40) is alternately connected to an effective resistance (41), an AC source inverter (42) or a magnetic switch (43) to provide a cost effective slip-energy-controlled, adjustable speed, induction motor that operates over a wide speed range from below synchronous speed to above synchronous speed based on the AC line frequency fed to the stator.

Abstract: A method of making a squirrel cage rotor of copper material for use in AC or DC motors, includes forming a core with longitudinal slots, inserting bars of conductive material in the slots, with ends extending out of opposite ends of the core, and joining the end rings to the bars, wherein the conductive material of either the end rings or the bars is copper. Various methods of joining the end rings to the bars are disclosed including friction welding, current pulse welding and brazing, transient liquid phase joining and casting. Pressure is also applied to the end rings to improve contact and reduce areas of small or uneven contact between the bar ends and the end rings. Rotors made with such methods are also disclosed.

Abstract: A method and apparatus for field weakening in PM machines uses field weakening coils (35, 44, 45, 71, 72) to produce flux in one or more stators (34, 49, 63, 64), including a flux which counters flux normally produced in air gaps between the stator(s) (34, 49, 63, 64) and the rotor (20, 21, 41, 61) which carries the PM poles. Several modes of operation are introduced depending on the magnitude and polarity of current in the field weakening coils (35, 44, 45, 71, 72). The invention is particularly useful for, but not limited to, the electric vehicle drives and PM generators.

Abstract: A hybrid permanent magnet dc motor includes three sets of permanent magnets supported by the rotor and three sets of corresponding stators fastened to the surrounding frame. One set of magnets operates across a radial gap with a surrounding radial gap stator, and the other two sets of magnets operate off the respective ends of the rotor across respective axial gaps.

Abstract: A method and circuit is disclosed for soft-commutation of a direct current (DC) motor. An attenuation circuit is connected through auxiliary brushes A, A', B and B' to the commutator (16) to drain circuit from successive armature coils (15) before the main brushes (27, 28) disconnects from each of the coils (15). This prevents the spark generation that normally occurs in conventional DC motors. The attenuation circuit may also be connected before energization of the coil (15) for a soft turning on operation.