Abstract: An alternator-starter system is coupled with an engine and includes an electric machine, an inverter/rectifier, a plurality of batteries, a plurality of switches and at least one controller. The switches are operable to connect the plurality of batteries in series or in parallel. The batteries are connected in series to supply a torque to the engine to start the engine and, under at least some conditions, the batteries are connected in parallel to charge the batteries. The batteries may also be individually charged or charged in series. In some embodiments, when the rotational speed of the electric machine exceeds a first threshold, the system is operated in the generating mode with the batteries being connected in parallel until a larger second threshold is exceeded and the batteries are connected in series. A method of operating an alternator-starter system is also disclosed.

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: 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: 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 including a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger, and at least one solenoid assembly capable of holding the plunger, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit that is capable of being activated by the plunger to control current flowing to at least a portion of the circuit. Some embodiments include at least two power isolation switches capable of controlling a current flow within the circuit.

Abstract: A starter assembly adapted for use with an engine having a flywheel and electronic control unit. The starter includes a motor, magnetic field source and a pinion gear engageable with the flywheel. An internal power train transmits torque from the armature to the pinion gear and includes a gear set dividing the internal power train into a first segment with the armature and a second segment with the pinion gear. During operation the first segment has a faster rotational speed than the second segment. A speed sensor senses the speed of the first segment and communicates it to the electronic control unit. The starter assembly can be used in a vehicle with an automatic start-stop function and facilitates the synchronizing of the pinion gear and flywheel speeds when restarting the engine. The speed sensor can take various forms and is advantageously supported on the field frame assembly proximate the commutator.

Abstract: An alternator-starter system and method is disclosed. A method of operating an alternator-starter having an inverter/rectifier for starting an engine and charging a plurality of batteries includes providing two switches for each battery, monitoring voltages of each of the plurality of batteries, and switching the switches to selectively charge individual ones of the plurality of batteries. A system includes a plurality of batteries connected in series, and includes first and second switches for each battery, the first switch being operable to switchably connect the upper rail of the inverter/rectifier with the respective (+) terminal, the second switch being operable to switchably connect the lower rail of the inverter/rectifier with the respective (?) terminal. A high voltage configuration may be utilized for motoring and generating modes.

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: 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 variable flux starter and switch system including a starter motor with motor field winding first and second portions, a control unit capable of selectively issuing starter activation and desired flux level signals, a motor energizing switch moveable between open and closed positions consequent to issuance of the starter activation signal, and a regulating device that transitions between default and activated operational states consequent to issuance of the flux level signal. The regulating device has a moveable blocking member and relatively moveable contact members, and in one of the default and activated operational states, electrical contact between the contact members is permitted or prevented by the blocking member. Current through the closed motor energizing switch substantially bypasses a motor field winding portion when electrical contact between the contact members is permitted, and is conducted through both portions when prevented. Also, a method for varying starter motor flux levels.

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 stator core includes a plurality of stator teeth. The plurality of stator teeth defines a plurality of slots. Each of the plurality of slots includes a first side, a second side, and a base joining the first and second sides. A slot liner is arranged in at least one of the plurality of slots. The slot liner includes a first side portion, a second side portion, and a base portion. The first side portion extends from a first end to a second end joining the base portion through a first intermediate portion. The second side portion extends from a first end to a second end joining the base portion through a second intermediate portion. A bend is formed in the first intermediate portion. The bend creates a gap between the first side portion and the first side.

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: 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 including a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger, and at least one solenoid assembly capable of holding the plunger, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit that is capable of being activated by the plunger to control current flowing to at least a portion of the circuit. Some embodiments include at least two power isolation switches capable of controlling a current flow within the circuit.

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.

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: 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: 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 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 alternator-starter system and method is disclosed. A method of operating an alternator-starter having an inverter/rectifier for starting an engine and charging a plurality of batteries includes providing two switches for each battery, monitoring voltages of each of the plurality of batteries, and switching the switches to selectively charge individual ones of the plurality of batteries. A system includes a plurality of batteries connected in series, and includes first and second switches for each battery, the first switch being operable to switchably connect the upper rail of the inverter/rectifier with the respective (+) terminal, the second switch being operable to switchably connect the lower rail of the inverter/rectifier with the respective (?) terminal. A high voltage configuration may be utilized for motoring and generating modes.

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.