Abstract: Rectangular conductor wires (38) are often used in alternator applications requiring a high slot fill to maximize output and efficiency. However for lower output and efficiency applications, round conductor (40) wire may increase cost competiveness in these alternators. A common lamination for a core (110) alternatively accommodates both rectangular conductor wires (38) and round conductor wires (40) for different applications without any other component changes. The lamina has a slot (112) that aligns round wire (40) in a single row within the slot and provides a predetermined clearance from the slot opening (126). A stator core (110) formed from these laminae has a relatively high slot fill factor when wound with the round wire (40). The same stator core (110) can be alternatively wound with square wire (38) to increase the slot fill factor even higher. The common lamination results in two stator configurations: a high slot fill version (round wire) and a very high slot fill version (square wire).

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: An alternator includes a housing, and a stator fixedly mounted relative to the housing. The stator includes a stator winding. The stator winding includes at least five stator leads extending from the stator in an arc that is less than about 90°. A terminal assembly is mounted to an outer surface of the housing and connected with 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 plurality of input connectors spread out along the body in an arc that is greater than 90°.

Abstract: An electric machine component includes a rotor assembly having at least one claw pole member having a number of pole members, an outer fan member support surface, and a central hub projecting from the outer fan member support surface. The central hub includes an anti-rotation member and a substantially planar bearing surface.

Abstract: An electronics package for an alternator includes an electrically conductive carrier member and a terminal assembly engaging the carrier member. The carrier member includes an inner side, an outer side, and at least one passage extending from the inner side to the outer side. A plurality of switches are connected to the carrier member. The terminal assembly includes an electrically insulative portion and a plurality of electrical traces extending through the electrically insulative portion. The electrically insulative portion includes a post extending through the at least one passage of the carrier member, a first shoulder engaging the outer side of the carrier member, and a second shoulder engaging the inner side of the carrier member. The post, the first shoulder, and second shoulder are all formed as a unitary component.

Abstract: A starter assembly is provided and includes a shaft to transmit rotation to a ring gear via a pinion and including a first helical spline with angling directed reversely with respect to a direction of the rotation and an elastic element anchored on the first helical spline to bias the pinion in an axial direction. The ring gear and the pinion include complementary teeth and the pinion defines a bore with a second helical spline to register with the first helical spline such that the pinion teeth are forwardly rotated into ring gear teeth engagement positions as the shaft moves axially relative to the pinion in the axial direction.

Abstract: A vehicle system is provided and includes a 12 volt alternator and a 24 volt wound rotor configured for acceptance in the 12 volt alternator.

Abstract: An alternator fan includes a base member having a central hub, an outer peripheral edge, and a web that extends between the central hub and the outer peripheral edge, and a plurality of openings extending through web. A plurality of fan blade elements is arranged in corresponding ones of each of the plurality of openings.

Abstract: An alternator includes a housing, and a stator fixedly mounted relative to the housing. The stator includes a stator winding. The stator winding includes at least five stator leads extending from the stator in an arc that is less than about 90°. A terminal assembly is mounted to an outer surface of the housing and connected with 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 plurality of input connectors spread out along the body in an arc that is greater than 90°.

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 component includes a rotor assembly having a body provided with a number of pole members and a central hub. The body includes at least one mounting member projecting radially outwardly of the central hub. A fan member is mounted to the rotor. The fan member includes a hub portion and a number of fan blades projecting radially outwardly from the hub portion. The fan member includes at least one mounting element extending radially outwardly of the hub portion. The at least one mounting element is configured and disposed to engage with the at least one mounting member to radially and axially constrain the fan member to the rotor.

Abstract: Some embodiments of the invention provide a starter system including a starter, capable of being in communication with an electronic control unit. The starter can include a motor coupled to a circuit and a pinion including a plunger, and a plurality of solenoid assemblies that includes a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger to move the pinion, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit. In some embodiments, the first switch is capable of being activated by the plunger to cause current to flow, or to prevent current flowing to at least a portion of the circuit.

Abstract: An internal combustion engine includes a ring gear, a speed sensor operatively associated with the ring gear, and a change of mind (COM) starter motor mechanically linked to the internal combustion engine. The COM starter motor includes an armature and a pinion operatively connected to the armature. A solenoid is operatively connected to the COM starter motor. The solenoid selectively moves the pinion into engagement with the ring gear. An electronic control unit (ECU) is operatively connected to the speed sensor and the solenoid. The ECU is configured and disposed to indirectly detect a rotational speed of the pinion and selectively energize the solenoid to axially shift the pinion into engagement with the ring gear when the pinion reaches a particular rotational speed relative to a rotational speed of the ring gear.

Abstract: A brush holder assembly for an alternator having a rotational axis includes a pair of brushes each having a contacting surface defining a width and a height, and each having a shunt wire extending laterally from the brush in the widthwise direction. The brush holder assembly includes a housing having first and second brush chambers, corresponding first and second wire cavities each defining a cavity height, and first and second slots respectively interposed between the corresponding chamber and cavity. The respective shunt wires extend through the first and second slots then through the first and second wire cavities. The cavity heights are each at least approximately 0.9 times the height of one of the brushes. The height of the first wire cavity is less than approximately 0.97 times ((A/2) plus B), wherein A is the brush height and B is the distance between the brushes.

Abstract: A method of inserting a continuous conductor having a rectangular cross-section into slot segments formed in a stator core includes forming a core member having a plurality of slot segments each having an opening and inserting a stator winding having a plurality of phases into select ones of the slot segments. Each of the plurality of phases has at least one conductor including a plurality of substantially straight segments alternately connected by a plurality of end loop segments. A section of the at least one conductor includes three consecutive end loop segments and three consecutive straight segments formed from a single continuous conductor. The method further includes narrowing the opening of each of the plurality of slot segments by forming an annular stator core having a central axis. The three consecutive straight segments are substantially similarly radially spaced from the central axis.

Abstract: A diagnostic system and method for a vehicle with a starter-based stop-start system. At least one diagnostic check is performed before stopping the engine as a function of the stop-start system. Both diagnostic checks may be performed. If a diagnostic check indicates a failure of the starter motor or solenoid, operation of the stop-start system is suspended. The system utilizes a sensor to determine if the starter shaft is rotating when the shaft is in a position wherein a gear on the shaft is disengaged. Operability of the starter motor is checked by energizing and then de-energizing the motor without engaging the gear and determining if the shaft rotates. Operability of the solenoid is checked by sensing the rotation of the starter shaft and then energizing the solenoid to move the shaft into a position where the sensor cannot detect rotation of the shaft.

Abstract: An electric machine includes a core with a plurality of teeth that extends between end faces of the core. Slots are defined in the core between adjacent teeth of the plurality of teeth. The slots each have a radial opening formed between end portions of the adjacent teeth. An insulation sheet is positioned on the core to obstruct the radial openings to the slots. The insulation has at least two spaced circumferential members that respectively overlap the end faces of the core. The insulation sheet also has a plurality of spaced axial members connected to the circumferential members. The axial members are positioned within the slots to obstruct the radial openings to the slots.

Abstract: An internal combustion engine includes a ring gear having a plurality of ring gear teeth. Each of the plurality of ring gear teeth includes a leading edge surface and a trailing edge surface. A starter motor is mounted to the internal combustion engine. The starter motor includes a pinion gear having a plurality of pinion gear teeth configured and disposed to selectively engage with the plurality of ring gear teeth. Each of the plurality of pinion gear teeth includes a leading edge surface portion and a trailing edge surface portion. The pinion gear is configured and disposed to engage with the ring gear while the ring gear is coasting. At least one of the trailing edge surface of each of the plurality of ring gear teeth and the leading edge surface portion of each of the plurality of pinion gear teeth includes a chamfer.

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 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.