Abstract: A position sensor includes a plurality of E-shaped ferromagnetic cores arranged to define a circular opening therethrough to receive a shaft. Each E-shaped ferromagnetic core has a plurality of teeth, wherein adjacent E-shaped ferromagnetic cores of the arranged plurality of E-shaped ferromagnetic cores have an overlapping tooth. The position sensor further includes a frame surrounding the arranged plurality of E-shaped ferromagnetic cores, with the E-shaped ferromagnetic cores coupled to the frame.

Abstract: Axial magnetic bearings that include a primary winding(s) and one or more compensation windings that provide compensation such that operation of the first and/or second primary windings and the compensation windings results in a net magneto-motive force of around zero ampere turns. Current can selectively flow through one or both of the primary windings of an opposing pair of axial magnetic bearings, while current flows through the compensation windings in manner that compensates for the magneto-motive force generated by the primary winding(s). In at least situations in which the number of turns for at least one pair of compensation windings is generally equal to the number of turns of each primary winding, the net magneto-motive force generated by current flowing through a primary winding of one axial magnetic bearing and through the compensation windings of both axial magnetic bearings can generally be zero.

Abstract: A method of making a permanent magnet rotor includes interference fitting pressure tools into bores in a rotor core as to deform material of the rotor core outwardly to bias permanent magnets mounted thereon in a radially outward direction against a fixation sleeve.

Abstract: An electrical rotor machine and a method of manufacturing the same are disclosed. According to at least one aspect of the present disclosure, the method includes forming a stator core from two or more subcores and inserting the separate subcores into a housing before windings are wound through and around the subcores to form a stator. In such embodiments, the housing includes a locating feature structured to position and support the subcores such that a flow channel is formed between the subcores. The locating feature enables both radial and axial cooling of the stator core while reducing pressure losses within the cooling flow path.

Abstract: Unique systems, methods, techniques and apparatuses of active magnetic bearing control systems are disclosed. One exemplary embodiment is a power converter electrically coupled to an active magnetic bearing (AMB) having a plurality of windings, the power converter comprising a DC bus, two capacitors, a first leg, a second leg, and a controller. The capacitors are electrically coupled in series between the positive rail and negative rail, one capacitor being electrically coupled to the other capacitor at a midpoint connection. The first leg comprises a first semiconductor switching device and a first output node. The second leg comprises a second semiconductor switching device and a second output node. The first output node is electrically coupled to the midpoint connection by way of a first AMB winding and the second output node is electrically coupled to the midpoint connection by way of a second AMB winding.

Abstract: An electrical rotor machine and a method of manufacturing the same are disclosed. According to at least one aspect of the present disclosure, the method includes forming a stator core from two or more subcores and inserting the separate subcores into a housing before windings are wound through and around the subcores to form a stator. In such embodiments, the housing includes a locating feature structured to position and support the subcores such that a flow channel is formed between the subcores. The locating feature enables both radial and axial cooling of the stator core while reducing pressure losses within the cooling flow path.

Abstract: A method of making a machine system includes assembling sensing elements with a sensor frame, and contacting ferrite cores of the sensing elements with a locating tool to conform an arrangement of the sensing elements to a cylindrical shape of a surface of the locating tool. The sensing elements are secured to the sensor frame in the determined arrangement, and coupled with a housing of a machine system to monitor position of a rotatable component therein. The ferrite cores may be E-type cores, with bridge connections used to sensitize the sensing mechanism to displacement of a rotatable component in X, Y, and Z directions.

Abstract: An induction rotor assembly having an induction cage that is formed using a combination of liquid and solid materials. The first and second end plates of the induction cage may be fabricated before the casting of the conductors of the induction cage. According to certain embodiments, the first and second end plates may be assembled with first and second molds and a rotor core to form a casting assembly. A liquid casting material may be injected into the casting assembly, wherein the liquid casting material may solidify within one or more core passageways of the rotor core, thereby forming the conductors of the induction cage. The first and second end plates may also include flow channels that may be configured to facilitate the flow of the liquid casting material in the casting assembly, and increase the area of contact between the liquid casting material, when solidified, and the end plates.

Abstract: An electric motor having a rotor core with a rotatable shaft extending therethrough, and a stator positioned radially outward of the rotor core is disclosed herein. The stator can include at least one pair of first and second coils circumferentially positioned on opposing sides of the rotor. Each pair of the first and second coils includes first and second elements electronically isolated from one another. A first frequency converter is electrically connected to a first conductive wire and a second frequency converter is electrically connected to a second conductive wire. The first conductive wire is wound about the first element of the first coil and the first element of the second coil in series and the second conductive wire is wound about the second element of the first coil and the second element of the second coil in series.

Abstract: A symmetrical cooling system for an electric rotor machine that includes a passageway that is positioned between portions of the stator, and which provides a pathway for a cooling medium. Stator ducts positioned within the stator, or portions thereof, are in fluid communication with the passageway. Cooling medium may flow through the stator ducts from the passageway to ends of the stator so that the cooling medium only travels along a portion of the overall axial length of the stator. The symmetrical cooling system also includes an air gap that is positioned between the stator and the rotor, and which receives cooling medium from the passageway at a midsection of the air gap. Cooling medium received at the midsection of the air gap may then flow towards either first or second ends of the stator.

Abstract: Axial magnetic bearings that include a primary winding(s) and one or more compensation windings that provide compensation such that operation of the first and/or second primary windings and the compensation windings results in a net magneto-motive force of around zero ampere turns. Current can selectively flow through one or both of the primary windings of an opposing pair of axial magnetic bearings, while current flows through the compensation windings in manner that compensates for the magneto-motive force generated by the primary winding(s). In at least situations in which the number of turns for at least one pair of compensation windings is generally equal to the number of turns of each primary winding, the net magneto-motive force generated by current flowing through a primary winding of one axial magnetic bearing and through the compensation windings of both axial magnetic bearings can generally be zero.

Abstract: Unique systems, methods, techniques and apparatuses of active magnetic bearing control systems are disclosed. One exemplary embodiment is a power converter electrically coupled to an active magnetic bearing (AMB) having a plurality of windings, the power converter comprising a DC bus, two capacitors, a first leg, a second leg, and a controller. The capacitors are electrically coupled in series between the positive rail and negative rail, one capacitor being electrically coupled to the other capacitor at a midpoint connection. The first leg comprises a first semiconductor switching device and a first output node. The second leg comprises a second semiconductor switching device and a second output node. The first output node is electrically coupled to the midpoint connection by way of a first AMB winding and the second output node is electrically coupled to the midpoint connection by way of a second AMB winding.

Abstract: An electrical machine has passages in the rotor. The passages have an inlet port and an exit port disposed at different locations. The passages remove heat from the electrical machine during operation. Another embodiment is an electrical machine rotor. The rotor has passages that remove heat from an electrical machine during operation. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for electrical machines and the cooling of electrical machine rotors and/or stators.

Abstract: A method of making a permanent magnet rotor includes interference fitting pressure tools into bores in a rotor core as to deform material of the rotor core outwardly to bias permanent magnets mounted thereon in a radially outward direction against a fixation sleeve.

Abstract: A method of manufacturing an electrical machine includes selecting a desired threshold control current, selecting dimensions to modify stator teeth of a magnetic bearing based on the desired threshold control current, and modifying the stator teeth using the selected dimensions. A method of producing a rotating machine includes selecting an operating point of a magnetic bearing of the rotating machine, and shaping at least some stator teeth of the magnetic bearing to generate increased force at control currents above the control current at the selected operating point.

Abstract: A method for making a chloride based mineral food salt that contains sodium, potassium and magnesium comprises combining a carnallite-containing concentrated solution and a potassium chloride in an amount that corresponds to the desired potassium content in the final product. Sodium chloride is added a calculated amount to the formed salt mass for absorbing water, and the product is dried.

Abstract: A method of making a machine system includes assembling sensing elements with a sensor frame, and contacting ferrite cores of the sensing elements with a locating tool to conform an arrangement of the sensing elements to a cylindrical shape of a surface of the locating tool. The sensing elements are secured to the sensor frame in the determined arrangement, and coupled with a housing of a machine system to monitor position of a rotatable component therein. The ferrite cores may be E-type cores, with bridge connections used to sensitize the sensing mechanism to displacement of a rotatable component in X, Y, and Z directions.

Abstract: An electrical rotor machine and a method of manufacturing the same are disclosed. According to at least one aspect of the present disclosure, the method includes forming a stator core from two or more subcores and inserting the separate subcores into a housing before windings are wound through and around the subcores to form a stator. In such embodiments, the housing includes a locating feature structured to position and support the subcores such that a flow channel is formed between the subcores. The locating feature enables both radial and axial cooling of the stator core while reducing pressure losses within the cooling flow path.

Abstract: A symmetrical cooling system for an electric rotor machine that includes a passageway that is positioned between portions of the stator, and which provides a pathway for a cooling medium. Stator ducts positioned within the stator, or portions thereof, are in fluid communication with the passageway. Cooling medium may flow through the suitor ducts from the passageway to ends of the stator so that the cooling medium only travels along a portion of the overall axial length of the stator. The symmetrical cooling system also includes an air gap dial is positioned between the stator and the rotor, and which receives cooling medium from the passageway at a midsection of the air gap. Cooling medium received at the midsection of the air gap may then flow towards either first or second ends of the stator.

Abstract: A method for making a chloride based mineral food salt that contains sodium, potassium and magnesium comprises combining a carnallite-containing concentrated solution and a potassium chloride in an amount that corresponds to the desired potassium content in the final product. Sodium chloride is added a calculated amount to the formed salt mass for absorbing water, and the product is dried.