Abstract: A solenoid for a vehicle starter includes at least one coil with a passage extending through the coil. A plunger is slideably positioned within the passage and configured to move in an axial direction between a first position and a second position. The plunger includes a substantially cylindrical outer surface portion with a circumferential notch formed in the outer surface portion. The at least one coil may include a pull-in coil and a hold-in coil wound on a spool. A plate member is positioned at one end of the spool and is separated from the plunger by a radial distance. The radial distance varies when the plunger moves in the axial direction as a result of the notch moving in relation to the plate member. A sleeve member may be coupled to the plunger such that the sleeve member covers the circumferential notch formed in the plunger.

Abstract: A solenoid arrangement for a starter motor includes a plunger configured to move in an axial direction and a coil positioned radially outward from the plunger. The coil is wound on a spool that includes a first end and a second end with a hub extending between the first end and the second end. A projection is positioned on the hub of the spool. The coil engages the projection in such a manner that a winding direction of the coil is reversed at the projection.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine. The electric machine includes a stator assembly with a plurality of stator laminations. The plurality of stator laminations include a plurality of different outer diameters and some of the plurality of stator laminations include at least two different radii. At least one circumferential coolant channel and at least one axial coolant channel can be defined by the plurality of stator laminations. The at least one circumferential coolant channel can be defined substantially around a circumference of the stator assembly and the at least one axial coolant channel can be defined substantially along an axial length of the stator assembly.

Abstract: An electric machine including a housing, and a stator mounted relative to the housing. The stator includes a body including a first end portion that extends to a second end portion and a plurality of stator windings that extend between the first and second end portions. A sleeve member is mounted to the stator and covers a portion of the stator windings at one of the first and second end portions. The sleeve member is configured and disposed to guide a coolant over the portion of the stator windings to remove heat from the stator.

Abstract: A solenoid for a vehicle starter comprises a pull-in coil and a hold-in coil positioned axially adjacent to the pull-in coil. A plunger is positioned within the pull-in coil and configured to move in an axial direction when the pull-in coil is energized. The plunger is separated from a plunger stop in the axial direction by an air gap when the pull-in coil and the hold-in coil are not energized. When the pull-in coil and hold-in coil are energized, a shoulder of the plunger moves in an axial direction toward the plunger stop. The pull-in coil is positioned in the solenoid such that it is removed from the plunger stop in the axial direction. In contrast, the hold-in coil encircles the plunger stop.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine positioned with a housing. The brushless electric machine including a center axis of rotation and a support member with a field coil wound around a portion of the support member. The electric machine includes a rotor assembly circumscribing the support member and a shaft coupled to a rotor assembly. The machine also include a stator assembly including a distributed stator winding comprising a plurality of conductors positioned within the stator assembly. The module also includes a cooling system, which includes an inlet disposed through a portion of the housing, a first channel positioned within the support member that fluidly connects a second channel with the inlet.

Abstract: Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity, a coolant jacket, and at least one coolant aperture positioned through a portion of the housing so that the coolant jacket is fluidly connected to the machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and includes a stator assembly. The stator assembly includes a stator core with slots. The stator core can include a weld side and an insertion side. In some embodiments, conductors can be positioned in the slots so that portions of the conductors axially extend from the weld side and the insertion side of the stator core. In some embodiments, at least some of the conductors can be configured and arranged to define a substantially radially-directed aperture between portions of the conductors on the weld side.

Abstract: An electrical system for a vehicle comprises a battery including a positive terminal and a negative terminal, and an alternator. The alternator includes a metal housing with a rotor and a stator positioned within the housing. The alternator further includes an electronics package positioned on the alternator housing. The electronics package includes a regulator and a rectifier, the rectifier including a plurality of negative diodes and a plurality of positive diodes. The plurality of positive diodes are positioned on a first diode carrier that is electrically connected to the negative terminal of the battery. The plurality of positive diodes are positioned on a second diode carrier that is electrically connected to the positive terminal of the battery. The first diode carrier is separated from the housing by an electrical insulation member positioned between the first diode carrier and the housing.

Abstract: An electric machine includes a stator and a rotor configured to rotate about an axis of rotation in a direction of angular rotation. The rotor includes a first claw-pole segment and an opposing second claw-pole segment. The first claw-pole segment includes a plurality of fingers extending from an end ring. Each finger includes a distal end and a proximal end with the proximal end fixed to the end ring. Each finger also includes an interior side and an exterior side with the exterior side facing the stator. A leading side and a trailing side are defined on each finger by the direction of angular rotation. A chamfer is formed on the exterior trailing side of each finger at the proximal end of the finger.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module includes the electric machine including a stator with stator end turns and a housing enclosing the electric machine. An inner wall of the housing defines a machine cavity. The electric machine module also includes a cover coupled to the housing and extending radially inward into the machine cavity. The cover and the stator end turns define a stator cavity which is in fluid communication with the machine cavity.

Abstract: A vehicle alternator comprises a rotor and a stator positioned within a housing. The housing includes a front face, a rear face, and a outer wall extending between the front face and the rear face. The front face includes a plurality of air inlet holes, and the rear face including a plurality of air outlet holes. The outer wall is void of air holes that extend through the outer wall. The rotor is positioned within the housing and configured to rotate about an axis. The stator is positioned within the housing between the rotor and the outer wall of the housing. The stator includes a core with an outer surface, a front end and a rear end. A plurality of substantially axial air passages are positioned between the outer wall of the housing and the outer surface of the stator core.

Abstract: Some embodiments of the invention provide an electric machine module including a rotor assembly. The rotor assembly can include a rotor hub, a first set of rotor laminations which can include a portion having a first inner radius, and a second set of rotor laminations which can include a portion having a second inner radius larger than the first inner radius. At least one circumferential flow channel defined by the first set of rotor laminations, the second set of rotor laminations, and the rotor hub can at least partially circumscribe the rotor hub.

Abstract: Embodiments of the invention provide an electric machine module including module housing with an inner wall and at least one end cap. The module can at least partially define a machine cavity. The electric machine module can also include at least two drain holes positioned substantially circumferentially apart from one another and extending through a lower portion of the module housing. The at least two drain holes can provide gravity-fed fluid pathways out of the machine cavity.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine with a stator assembly. The stator assembly includes a plurality of stator laminations coupled together and a plurality of conductors positioned through axial slots of the plurality of stator laminations. The electric machine module also includes a coolant channel at least partially defined within the axial slots and a housing. The housing at least partially circumscribes the electric machine and at least partially defines a machine cavity which is in fluid communication with the coolant channel.

Abstract: Embodiments of the invention provide a coolant drainage system including a module housing and a drain pan coupled to the module housing. The module housing at least partially defines a machine cavity and includes an inner wall and at least one end cap at least partially enclosing an electric machine within the machine cavity. The coolant drainage system also includes a plurality of drain holes through the module housing and adjacent to the drain pan. The plurality of drain holes provide fluid pathways from the machine cavity to the drain pan.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine. The electric machine includes a stator assembly with a plurality of stator laminations. The plurality of stator laminations include a plurality of different outer diameters and some of the plurality of stator laminations include at least two different radii. At least one circumferential coolant channel and at least one axial coolant channel can be defined by the plurality of stator laminations. The at least one circumferential coolant channel can be defined substantially around a circumference of the stator assembly and the at least one axial coolant channel can be defined substantially along an axial length of the stator assembly.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine with a stator assembly. The stator assembly includes a plurality of stator laminations and the plurality of stator laminations include a plurality of different outer diameters. The plurality of stator laminations are positioned relative to one another to form radially-extending fins. At least one circumferential coolant channel is defined along the circumference of the stator assembly by the plurality of stator laminations at least partially between the radially-extending fins.

Abstract: Embodiments of the invention provide an electric machine module comprising an electric machine with a stator and housing at least partially circumscribing the electric machine. The housing includes at least two housing members coupled together and substantially securing the electric machine within the housing. The electric machine module also includes a coolant jacket at least partially defined by an outer diameter of the stator and an inner diameter portion of the housing.

Abstract: A solenoid for a vehicle starter comprises a spool including a first coil bay, a second coil bay, and an interior passage defining an axial direction. A first coil is positioned in the first coil bay of the spool, and a second coil positioned in the second coil bay of the spool. A plunger is positioned within the interior passage of the spool and configured to move in the axial direction when the first coil is energized. The first coil bay is positioned adjacent to the second coil bay in the axial direction. The spool further includes two end flanges and a middle flange. The middle flange separates the first coil bay from the second coil bay.

Abstract: A solenoid for a vehicle starter includes at least one coil with a passage extending through the coil. A plunger is slideably positioned within the passage and configured to move in an axial direction between a first position and a second position. The plunger includes a substantially cylindrical outer surface portion with a circumferential notch formed in the outer surface portion. The at least one coil may include a pull-in coil and a hold-in coil wound on a spool. A plate member is positioned at one end of the spool and is separated from the plunger by a radial distance. The radial distance varies when the plunger moves in the axial direction as a result of the notch moving in relation to the plate member. A sleeve member may be coupled to the plunger such that the sleeve member covers the circumferential notch formed in the plunger.