Abstract: An electric motor or generator assembly includes a component, such as a stator, having a plurality of windings. A wire set including a plurality of individually conductive wires twisted together is manipulated within a core to establish the desired number of windings having the desired cross sectional area. In one example, a plurality of such wire sets are manipulated simultaneously to establish the windings. Litz wire is one example type of wire set that is useful in an assembly designed according to this invention. There are more than 100 individual wires within each winding according to one example stator designed according to this invention.

Abstract: An improved braking apparatus having a jaw type clutch coupled to an electrical solenoid through a ball spline mechanism provides significantly greater braking capacity in a given volume than other types of braking devices. The ball spline is configured to significantly reduce the internal friction load which the electrical solenoid must overcome to apply or release the brake, resulting in a smaller physical size and current draw of the solenoid. The jaw clutch and ball spline are also configured to reduce or absorb shock loads on various internal components of the braking apparatus when the brake is engaged. By configuring the ball spline and jaw clutch to function as shock absorbers in addition to performing their primary functions, the need for separate elastomeric shock absorbers, etc., is eliminated.

Abstract: Long thermal paths and the resulting slow response times in sealed and electrically insulated thermal sensors may be substantially reduced by insulating and sealing the sensor (26) by a method which includes the steps of providing (30) an electrostatic fluidized bed of electrically insulating resin; locating (34) the sensor (26) at the bed; coating (36) the sensor (26); removing (38) the sensor from proximity to the bed; and curing (40) to the resin to form a uniform, thin coating encapsulating the sensor (26).

Abstract: Difficulties in sensing the temperature of end turns in dynamoelectric machines are avoided through the use of an envelope containing a temperature sensor disposed between abutting sets of end turns in such machine. The envelope has two insulating plies formed of insulating material sandwiching a ply formed of metal having excellent thermal conductivity. The latter is bonded to the former such that an exposed edge of the insulating plies exists by which the envelope may be closed to totally encapsulate the metal ply.

Abstract: A rotor assembly for a rotary electric machine including a magnetic shaft provided with at least one pair of equiangularly spaced flats. Non-magnetic spacers abut the flats and a plurality of arcuate permanent magnet segments are disposed about the shaft between the spacers. A plurality of magnetic pole pieces are disposed radially outwardly of a corresponding one of the magnets and are disposed between adjacent spacers. Generally C-shaped channels of non-magnetic material overlie the spacers and interconnect adjacent ends of adjacent pole pieces to hold the components of the rotor in assembled relation.