Abstract: An alternator assembly powered by a pulley is made up of an outer housing that contains the stator and rotor assemblies, an inner housing and a rear cover which is retained by a fastening member that secures the inner housing and rear cover within the outer housing.

Abstract: An alternator assembly 10 having a pair of housing members 11, 12 which cooperatively contain a stator 24, rotor 18, and bearing 29. The housing member 12 includes an integrally formed bearing sleeve member 40 which receives the bearing 29 and allows the rotor 18 to rotate within the assembly 10.

Abstract: An alternator includes an inner housing and an outer housing. A pair of o-rings positioned therebetween create a sealed flow chamber having a first flow channel, a second flow channel and an axial passageway. The first flow channel is a disk shaped cavity extending diametrically across the alternator. The second flow channel forms an annular jacket extending entirely around the alternator. The axial passageway directs coolant axially from the first flow channel into the second flow channel. An inlet positioned diametrically across from the axial passageway allows coolant to enter the first flow channel, such that coolant entering the inlet must flow diametrically across the alternator to reach the axial passageway. An outlet positioned diametrically across from the axial passageway allows coolant to exit the flow chamber, such that coolant entering the second flow channel must travel annularly around the alternator to reach the outlet.

Abstract: An alternator includes an inner housing and an outer housing. A pair of o-rings positioned therebetween create a sealed flow chamber having a first flow channel, a second flow channel and an axial passageway. The first flow channel is a disk shaped cavity extending diametrically across the alternator. The second flow channel forms an annular jacket extending entirely around the alternator. The axial passageway directs coolant axially from the first flow channel into the second flow channel. An inlet positioned diametrically across from the axial passageway allows coolant to enter the first flow channel, such that coolant entering the inlet must flow diametrically across the alternator to reach the axial passageway. An outlet positioned diametrically across from the axial passageway allows coolant to exit the flow chamber, such that coolant entering the second flow channel must travel annularly around the alternator to reach the outlet.

Abstract: An alternator assembly 10 having a pair of housing members 11, 12 which cooperatively contain a stator 24, rotor 18, and bearing 29. The housing member 12 includes an integrally formed bearing sleeve member 40 which receives the bearing 29 and allows the rotor 18 to rotate within the assembly 10.

Abstract: An assembly (30) for use with a rotating electric machine has a first injection-molded plastic part (32), a second injection-molded plastic part (34), and a third injection-molded plastic part (36). Parts (32, 34) are a bearing sleeve and a brush holder respectively, while part (36) is a cap. The bearing sleeve has a transverse wall (138) from which channels (146, 148) extend in one direction. A cylindrical wall extends in the other direction to form a bearing cup (136) for receiving a bearing assembly. The brush holder has two side-by-side brush guides (62, 64) each containing a respective brush (38, 40). It also has two channels (110, 112) that interlock with the channels of the bearing sleeve to accurately and rigidly place the two parts (32, 34) in assembly. The cap closes an axial end of the bearing sleeve and attaches to the brush holder. The parts are further characterized by various structural features, as well as fabrication and assembly methods.

Abstract: An liquid-cooling system for an electrical machine comprises a rotor mounted on a shaft for rotation therewith and defining an axis of rotation, and a stator disposed coaxially with and in opposition to the rotor. The stator has stator windings, the stator windings having an axially-extending portion. The electrical machine further comprises a housing enclosing the stator and the rotor, the housing having an axial end, the axial end having a wall with an inner surface and an outer surface. The electrical machine also includes a cooling tube having a first end and a second end and an embedded portion thereof embedded between the first inner surface and the first outer surface, the embedded portion of the cooling tube located in substantial axial alignment with the axially-extending portion of the stator windings. In another aspect of this design, the inner surface of the wall of the axial end of the housing is substantially flat and is separated from an axial end of the rotor by an air gap.

Abstract: A rotating machine comprises a housing defining a generally cylindrical bearing pocket and defining an interior and exterior. The machine also includes a bearing retainer having a generally cylindrical sleeve portion retained in the bearing pocket and a bearing having an outer race and an inner race, the outer race affixed within the cylindrical sleeve portion. The machine further has a rotating member mounted on a shaft for rotation therewith, the shaft having a portion affixed within the inner race of the bearing. In one embodiment, the bearing retainer includes anti-rotation keying projections the bearing pocket includes complementary depressions for the keying projections. The keying projections cooperate with the complementary depressions to prevent rotation of the bearing retainer with respect to the bearing pocket. In another embodiment, a cap is affixed to the bearing retainer to substantially prevent contamination from reaching the bearing from the exterior.

Abstract: A rotor for an electrical machine according to one embodiment of the present invention comprises a shaft defining an axis of rotation of the rotor, and first and second pole pieces affixed to the shaft for rotation therewith and together defining an interior cavity. The rotor additionally includes a slip ring affixed to the shaft for rotation therewith. Further, the rotor comprises a field-generating coil disposed within the interior cavity, the coil comprising a plurality of turns of electrical wire, the electrical wire further having a section extending to and electrically coupled to the slip ring. Also, the rotor has a retainer disposed exterior to the cavity and adjacent the first pole piece, the retainer comprising a radially-extending channel containing a portion of the section of electrical wire.

Abstract: An alternator and method of forming an alternator with a rectifier internal to the alternator housing are disclosed in which a plurality of positive diodes and negative diodes each has a anode electrode and a cathode electrode. The stator of the alternator has a plurality of stator windings, each winding having a first end and a second end. The rectifier bridge member has electrically conductive circuit traces each having a plurality of substantially coplanar solder pads adapted to receive either an anode electrode of a respective positive diode, a cathode electrode of a respective negative diode or a first or second end of a respective stator winding. The rectifier bridge member also has an electrically conductive plate for electrically interconnecting the cathodes of the positive diodes. A housing for enclosing one end of the alternator has an interior and exterior portion.