Abstract: To facilitate assembly of an automotive alternator, the alternator housing (11) is separated into two axially split half-shells (11a, 11b), the dividing line (11c) preferably passing through the axis of the shaft (18) of the alternator. The alternator assembly is made by providing a subassembly including the shaft, electromagnetic rotor structure, bearings, and a disk element in which rectifier diodes are seated and which can also support holders in engagement with the slip rings and the voltage regulator. The stator is slipped around the subassembly, a fan wheel and pulley can be attached to the subassembly which is then placed into one half-shell. The bearings and the concentric elements are positioned in alignment by seats formed in the half-shell, and the axial alignment can be accurately checked, and if the alignment is found proper, the second half-shell is assembled thereover.

Abstract: The casing of the electric generator of a motor vehicle is made of two cylindrical shells, one located eccentrically with respect to the other, connected together by struts to provide a light-weight rigid relation between the two belts. The casing is then mounted in a saddle-shaped support affixed on a mounting surface. Because of the eccentric position of the generator shaft within the outer cylindrical shell of the casing, loosening the tension band that holds the generator in place and rotating the casing of the generator makes possible tightening or loosening of the V-belt that drives the generator.

Abstract: To form a compact combination structure which provides efficient cooling and ease of assembly, maintenance and repair, while reducing the number of elements necessary to be stocked for maintenance or repair purposes, the rectifier portion of the alternator-rectifier combination comprises two groups of rectifiers which are, respectively, set in openings of two disk-shaped support plates 15, 35, which have, each, ring-shaped portions 38 surrounding the shaft and radially projecting fins 39, 39'. One of the plates is formed with a hub to retain one of the bearings, the outer portion of the fins is apertured for attachment to the shell of the alternator, and additionally deformed to provide seating surfaces for accurate positioning, for example by externally applied punch marks, of the plate. An insulating spacer 43, 43' separates the two plates which are so positioned that the fins of one plate are opposite the gap between fins of the other, so that air drawn axially by a ventilating fan will cool both plates.

Abstract: To permit random selected positioning of an attachment arm (32) formed on the shell of an alternator with respect to a locating arm (33) thereon to tighten a drive belt driving the alternator from the engine, the locating arm (33) is integral with an end cover shield (12) attached to the shell (11). Preferably, the shell (11) is of hexagonal cross section, the shield (12) is likewise a hexagonal cross section, with attachment screws and screw openings in the corners of the hexagon to permit selected angular positioning of the locating arm and the attachment arm with respect to each other and match the configuration of the arms to different types of engines with which the alternator is to be used.

Abstract: To facilitate manufacture, and provide readily accessible insertion openings for rectifier diodes in automotive alternators, the end covers or end shields are made as sheet metal elements with radially extending arms, leaving space for ventilating openings therebetween, extending from the center of rotation of the alternator, and form with bearing retaining means at the center, for example in the form of a punch or drawn bushing extension extending in axial direction and at right angles to the major plane of the sheet metal element which, preferably, is also formed with stiffening ribs or beads at the lateral edges thereof. Preferably, the alternator is, in cross section, hexagonal and three arms, extending at 120.degree.

Abstract: To form a compact combination structure which provides efficient cooling and ease of assembly, maintenance and repair, while reducing the number of elements necessary to be stocked for maintenance or repair purposes, the rectifier portion of the alternator-rectifier combination comprises two groups of rectifiers which are, respectively, secured to the surface of two disk-shaped support plates 15, 35, which have, each, ring-shaped portions 38 surrounding the shaft and radially projecting fins 39, 39'. One of the plates is formed with a hub to retain one of the bearings, the outer portion of the fins is apertured for attachment to the shell of the alternator, and additionally deformed to provide seating surfaces for accurate positioning, for example by externally applied punch marks, of the plate.

Abstract: To direct cooling air to components which, in operation, require different amounts of cooling due to different heat dissipation, a cover cap is provided which prevents accidental contact with current-carrying elements and which is formed with slits or openings therein located with respect to the components requiring cooling to direct cooling air, upon induced axial airflow, to the respective components in relationship to their cooling requirements. Some of these openings may be formed with in-turned collars surrounding, for example, diode rectifiers, to direct air on and around the diode rectifiers, while preventing contact with their terminals.

Abstract: To provide an inexpensive assembly of a brush-holder and brush to engage the slip rings of an automotive-type alternator, particularly for low-cost, high-quantity mass production, a brush carrier arm, for example of leaf spring or circular spring material, is directly connected to hold a brush at one end thereof, for example by clamping the brush, securing it in a socket, or carrying an insulated brush-holder plate to which the brushes themselves are attached, the brush-holder arm being secured to a base which may be integral with, or form the cover of a housing for an electronic voltage regulator, so that the brush-holder itself will provide the spring engagement force for reliable electrical contact while permitting functioning also as an electrical connection and permitting inexpensive manufacture.

Abstract: A support carrier of electrically conductive material is secured to the shaft of the machine. A plurality of slip rings are secured to the support carrier, one of the slip rings being fixed thereto directly so that the support carrier will form one terminal of the electrical connection for the slip rings, and an insulating layer is placed over the support carrier over which the other slip ring is located. Preferably, the support carrier is formed with a flange which is notched, one of the notches serving to form an electrical connection for the wire of the field of the machine for connection to the slip ring which is directly secured to the support carrier, the other notch in the flange being wider and gripping around the insulation of the other wire of the field, the wire of the field then being connected to the slip ring which is carried on the insulation. That slip ring, preferably, is also formed with an external flange to which its connecting wire can be secured, for example by soldering.