Abstract: An electric machine a stator having a stator core and windings positioned thereon. The stator core has a plurality of slots formed therein and a winding positioned in the plurality of slots. The winding includes at least four parallel paths distributed in slot sets of the stator core. Each slot set includes at least four contiguous slots including two left slots and two right slots. A first parallel path and a second parallel path are arranged in the two left slots for at least a first revolution of the winding around the core. The first parallel path and the second parallel path are arranged in the two right slots for at least a subsequent revolution of the winding around the core.

Abstract: An electronics package for an alternator includes a positive carrier member having an inner side and an outer side, a plurality of switches connected to the positive carrier member, and a terminal assembly engaging the positive carrier member. The terminal assembly includes an electrically insulative portion and a plurality of electrical traces attached to the electrically insulative portion. The electrically insulative portion includes a post extending from the inner side to the outer side of the positive carrier member, a first shoulder engaging the outer side of the positive carrier member, and a second shoulder engaging the inner side of the positive carrier member. The second shoulder is provided by a deformed segment of the post. The post, first shoulder, and second shoulder are all formed as a unitary component.

Abstract: A method of installing a winding in a stator includes forming a first multi-conductor winding including a first plurality of terminal leads and a second plurality of terminal leads, forming a second multi-conductor winding including a third plurality of terminal leads and a fourth plurality of terminal leads, introducing the first multi-conductor winding into a plurality of stator slots of a stator body, introducing the second multi-conductor winding into the plurality of stator slots of the stator body radially inwardly of the first multi-conductor winding, and connecting the second plurality of terminal leads with the third plurality of terminal leads to form a twelve conductor stator winding.

Abstract: A method of forming a winding for an electric machine includes forming a plurality of conductors having a substantially identical wire form with a plurality of end turns joining a plurality of slot segments, defining a first portion of the plurality of conductors as first conductors, rotating a second portion of the plurality of conductors about a central axis to mirror the first conductors, defining the second portion of the plurality of conductors as second conductors, combining select ones of the first conductors and select ones of the second conductors to form conductor pairs, and combining a plurality of conductor pairs to form a multi-conductor winding.

Abstract: A method of forming a stator for an electric machine includes forming a first conductor and a second conductor into a plurality of bends having a first winding pitch, creating a winding layer by introducing the first conductor and the second conductor into a first pole of a stator with the second conductor being on top of the first conductor at a first end loop crossing zone. The winding pitch of the first conductor is changed to a second winding pitch and the winding pitch of the second conductor is changed to a third winding pitch. The first conductor is woven relative to the second conductor between the first pole and a second pole. The first conductor and the second conductor are introduced into the second pole of the stator with the first conductor being on top of the second conductor at a second end loop crossing zone.

Abstract: A motor vehicle solenoid includes a solenoid housing having an inner surface, at least one coil arranged in the housing, an actuator associated with the at least one coil, and a stop member arranged in the housing adjacent the at least one coil. The stop member includes an outer circumferential edge abutting the inner surface of the solenoid housing. The outer circumferential edge includes at least one clearance zone that is spaced from the inner surface of the housing. The at least one clearance zone defines a grounded electrical attachment surface.

Abstract: An electronics package for an alternator includes a positive carrier member having an inner side and an outer side, a plurality of switches connected to the positive carrier member, and a terminal assembly engaging the positive carrier member. The terminal assembly includes an electrically insulative portion and a plurality of electrical traces attached to the electrically insulative portion. The electrically insulative portion includes a post extending from the inner side to the outer side of the positive carrier member, a first shoulder engaging the outer side of the positive carrier member, and a second shoulder engaging the inner side of the positive carrier member. The second shoulder is provided by a deformed segment of the post. The post, first shoulder, and second shoulder are all formed as a unitary component.

Abstract: A method of making an electronics package for an alternator includes inserting a post of a terminal assembly thorough a hole in an electrically conductive carrier member such that the terminal assembly is positioned on a first side of the carrier member and an end portion of the post extends from a second side of the carrier member. The method further includes deforming the post extending through the hole on the second side of the carrier member such that the terminal assembly engages the second side of the carrier member and the carrier member is connected to the terminal assembly.

Abstract: A stator includes a cylindrical core with a plurality of longitudinally extending slots, a first winding set formed as a first cascaded wire in two radial layers of the slots, a second winding set formed as a second cascaded wire in two other radial layers of the slots, and a jumper connecting the first and second wires. A first winding set may have three cascaded phase wires in first and second layers of the slots, and a second winding set may have three cascaded phase wires in third and fourth layers of the slots. A winding set of a first phase may have a first cascaded wire in two radial layers of a first one of the slots, and a winding set of a second phase may have a second cascaded wire in two other radial layers of the first one of the slots.

Abstract: An electric machine having a rotor, stator and at least one winding. The winding defines a first lead having a conductive core and an electrically insulative exterior layer. A connector engaged with the first lead includes a plurality of projections that pierce the exterior layer of the first lead to engage the conductive core. The connector may be C-shaped having a spine and first and second arms with first and second bend lines respectively disposed between the spine and the two arms. Alternatively, the connector may be U-shaped having a spine and first and first and second arms wherein a bend line and a central opening are disposed between the two arms. The first lead extends through the central opening and is grippingly engaged by the connector between the first and second arms. The connector may also be used to securely engage an uninsulated terminal.

Abstract: A stator includes a cylindrical core with a plurality of longitudinally extending slots, a first winding set formed as a first cascaded wire in two radial layers of the slots, a second winding set formed as a second cascaded wire in two other radial layers of the slots, and a jumper connecting the first and second wires. A first winding set may have three cascaded phase wires in first and second layers of the slots, and a second winding set may have three cascaded phase wires in third and fourth layers of the slots. A winding set of a first phase may have a first cascaded wire in two radial layers of a first one of the slots, and a winding set of a second phase may have a second cascaded wire in two other radial layers of the first one of the slots.

Abstract: A wire forming apparatus comprises a first rack moveable relative to a second rack in a first direction, a plurality of first forming structures provided on the first rack, and a plurality of second forming structures provided on the second rack. Each of the plurality of first forming structures is configured to move in the first direction, is separated from an adjacent first forming structure, and is configured to move in a second direction closer to the adjacent first forming structure when the first rack moves relative to the second rack. Each of the plurality of second forming structures is configured to move in the first direction, is separated from an adjacent second forming structure, and is configured to move in the second direction closer to the adjacent second forming structure when the first rack moves relative to the second rack. The second direction is different from the first direction.

Abstract: A stator assembly (50) includes a stator core (52) defining an outside diameter (OD) and an inside diameter (ID) with longitudinally extending slots (58) formed between the inside diameter and the outside diameter. The stator core (52) defines a core height extending longitudinally from a first end (53) to a second end (55) of the stator core (52). Distributed windings (60) are retained by the stator core (52) and include an in-slot portion (66) positioned in the slots of the stator core (52), a first end turn portion (62) adjacent to the first end (53) of the stator core, and a second end turn portion (64) adjacent to a second end (55) of the stator core. The first end turn portion (62) defines a first end turn height (h1) extending from the first end (53) of the stator core to a vertex (78) of the first end turn portion (62). A ratio of the first end turn height (h1) to the outside diameter (OD) of the stator core is less than or equal to 0.07.

Abstract: An alternator including a housing, and a stator fixedly mounted relative to the housing. The stator includes a plurality of stator slots and a stator winding arranged in the plurality of stator slots. The stator winding includes at least five stator leads extending from five adjacent ones of the plurality of stator slots. A terminal assembly is mounted to an outer surface of the housing and is connected with at least three of the at least five stator leads. The terminal assembly includes a body formed from a non-electrically conductive material and a plurality of conductive members at least partially covered by the body. The plurality of conductive members is associated with the stator winding. Each of the plurality of conductive members includes a plurality of input connectors spread out along the body in an arc that is greater than 90°.

Abstract: A wire forming apparatus comprises a first rack moveable relative to a second rack in a first direction. Multiple forming structures are provided on the first rack and the second rack. The plurality of forming structures include a first plurality of forming structures configured to move relative to the first rack in a second direction, and a second plurality of forming structures configured to move relative to the second rack in the second direction. A plurality of are actuators are configured to move the first rack relative to the second rack, move the first plurality of forming structures relative to first rack, and move the second plurality of forming structures relative to the second rack.

Abstract: A method of securing a fan member to a rotor assembly of an electric machine. The method includes positioning the fan member adjacent the rotor, aligning at least two mounting members extending radially outwardly of the central hub of the rotor assembly with a corresponding at least two mounting elements extending radially inwardly of a hub portion of the fan member, and securing the at least two mounting members to the corresponding at least two mounting elements.

Abstract: An electric machine including a rotor and a stator and having a first winding. The stator slots define a plurality of layer positions wherein each of the layer positions is at a different radial distance from the axis. There is an odd number of select stator slots wherein for two slot segments disposed in different layer positions, a pair of end loops connect each of the slot segments with another slot segment in a different slot that is in the same layer position. In some embodiments, at least 60 percent of the end loops connect slot segments that are disposed in different layer positions. For some embodiments, only a single select stator slot is provided with the end loops being positioned to reduce spatial conflicts.

Abstract: A method of forming an insulated conductor, includes forming an insulated conductor to modify a cross sectional shape thereof. Heating at least a portion of the insulated conductor to a selected temperature range. Maintaining the selected temperature range for at least a selected period of time thereby annealing the conductor. Forming the insulated conductor into a plurality of gable shaped loops; and maintaining insulating properties of an insulation layer of the insulated conductor. Also included is a method of annealing an insulated conductor.

Abstract: An alternator including a housing, and a stator fixedly mounted relative to the housing. The stator includes a plurality of stator slots and a stator winding arranged in the plurality of stator slots. The stator winding includes at least five stator leads extending from five adjacent ones of the plurality of stator slots. A terminal assembly is mounted to an outer surface of the housing and is connected with at least three of the at least five stator leads. The terminal assembly includes a body formed from a non-electrically conductive material and a plurality of conductive members at least partially covered by the body. The plurality of conductive members is associated with the stator winding. Each of the plurality of conductive members includes a plurality of input connectors spread out along the body in an arc that is greater than 90°.

Abstract: An electric machine including a rotor and a stator and having a first winding. The stator slots define a plurality of layer positions wherein each of the layer positions is at a different radial distance from the axis. There is an odd number of select stator slots wherein for two slot segments disposed in different layer positions, a pair of end loops connect each of the slot segments with another slot segment in a different slot that is in the same layer position. In some embodiments, at least 60 percent of the end loops connect slot segments that are disposed in different layer positions. For some embodiments, only a single select stator slot is provided with the end loops being positioned to reduce spatial conflicts.