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 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 method of assembling a stator includes forming a plurality of cleats into a brazing tape, forming a U-shaped clip using the stamped brazing tape, and attaching the U-shaped clip to a stator conductor, where the attached U-shaped clip is self-secured to the conductor by the cleats. Apparatus for connecting a stator conductor pair includes a brazing clip shaped to conform to and fit over one of the conductors and having generally a U-shape with two sides each including at least one cleat configured to engage the one conductor and secure the respective side thereto. A system for brazing together adjacent pairs of conductors includes a self-securing, three-sided brazing clip having a plurality of cleats formed therein, a comb having a plurality of receptacles structured for retaining respective stator conductors, and electrodes radially aligned with one adjacent pair, where compression of the electrodes sandwiches the brazing clip therebetween.

Abstract: An apparatus for and a method of brazing copper armature conductors to a commutator during the production of automotive starting motors. In the inventive method, two conductors of the armature are brazed together and are also brazed to the corresponding slot in a commutator in a single step. The process is aided by an inventive brazing clip which includes a cleat or inwardly bent tab that engages the conductor of an armature to hold it in place.

Abstract: The method of the present invention involves setting a penetration threshold as well as a maximum weld time when hot staking armature conductors to the slots of a commutator. To perform each weld, an electrode is forcibly contacted with the top conductor in one of the slots of the commutator. Next, electric current is delivered to the electrode, causing the conductor to heat and begin to deform within the slot. During this time, the electrode moves further into the slot. If the electrode reaches the penetration threshold in the commutator slot before the maximum weld time is reached, current to the electrode is terminated. After terminating current to the electrode, the electrode remains in contact with and applies force to the conductor until the maximum weld time is reached. After the maximum weld time is reached, the electrode is removed from contact with welded conductor.

Abstract: The method of the present invention involves setting a penetration threshold as well as a maximum weld time when hot staking armature conductors to the slots of a commutator. To perform each weld, an electrode is forcibly contacted with the top conductor in one of the slots of the commutator. Next, electric current is delivered to the electrode, causing the conductor to heat and begin to deform within the slot. During this time, the electrode moves further into the slot. If the electrode reaches the penetration threshold in the commutator slot before the maximum weld time is reached, current to the electrode is terminated. After terminating current to the electrode, the electrode remains in contact with and applies force to the conductor until the maximum weld time is reached. After the maximum weld time is reached, the electrode is removed from contact with welded conductor.

Abstract: A method of securing a tubular metallic magnet retainer to a tubular metallic frame of a dynamoelectric machine, the tubular frame having an annular internal surface, the steps comprising, forming an annular end surface at an end of said tubular frame that is located at an angle to said annular internal surface of said frame, an intersection of said annular end surface and said internal annular surface of said frame forming an annular first ridge, inserting said magnet retainer into said tubular frame, bending an annular end portion of said magnet retainer into engagement with said annular surface on said frame to thereby form a second annular ridge on said magnet retainer that is aligned with said first annular ridge, moving a welding electrode that has an annular tapered surface into engagement with said second ridge, a shape of said tapered surface on said welding electrode being such that there is annular line contact between a portion of said tapered surface on said welding electrode and said second ridg

Abstract: A frame and magnet assembly for a dynamoelectric machine. The assembly includes an imperforate frame member formed of metallic magnetic material. A one-piece tubular imperforate stainless steel magnet supporting part is disposed within the frame. The magnet supporting part has pockets that contain permanent magnets. The opposite ends of the frame have annular chamfered or tapered surfaces which intersect a tubular inner surface of the frame to define annular ridges. Annular end portions of the magnet support are bent into engagement with the tapered surfaces on the frame to thereby provide ridges on the magnet support that are aligned with the ridges on the frame. The ridges on the frame are welded to the ridges on the magnet support by a welding current that is supplied to a pair of welding electrodes that respectively engage the ridges on the magnet support. The welding electrodes have annular tapered surfaces which have line contact with the ridges on the magnet support.