Abstract: A partial discharge calibration standard apparatus may include a first and second rigid members defining respective first and second facing surfaces. An electrically insulating material may be disposed between the facing surfaces. The apparatus may further include a pressure member maintaining the rigid members together, thereby fixing the first and second facing surfaces in a substantially parallel spaced relation across the insulating material such that a partial discharge threshold magnitude for an electrical potential difference between the first and second facing surfaces is determined.

Abstract: A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Abstract: An additive manufacturing system includes a powder delivery system, an area scanning laser, a build chamber, and a controller. The powder delivery system provides a predetermined amount of powder material to the build chamber, and includes a material dispenser, a dispensing head, and a scraper. The scanning laser selectively sinters the powder material, and includes a mirror galvanometer for raster scanning. The build chamber has an annular configuration, and includes an inner annular wall that defines a central portion disposed inward of the build chamber. A portion of the delivery system and the laser are located in the central portion. The chamber continuously rotates under the head and under a sintering zone generated by the laser as the delivery system continuously dispenses the material. The laser continuously raster scans the material at the sintering zone in a raster pattern to sinter a layer of material directly to a preceding layer.

Abstract: A method for manufacturing a stator includes the steps of: (1) providing a stator core module having a first stator fixture disposed on a first side of the stator core module, the first stator fixture is configured to support a first set of stator core junction portions in a fixed position; (2) providing a first crown module having a set of first crown junction portions and a first crown fixture to support the first set of first crown junction portions; (3) aligning the first stator fixture with the first crown fixture so that the first set of stator core junction portions are aligned with the first crown junction portions; and (4) joining the first set of stator core junction portions with the first crown junction portions.

Abstract: A method for manufacturing an induction rotor includes placing a lamination stack into a fixture in which the first end of the lamination stack is rotated in an opposite rotational direction from the second end of the lamination stack to skew the conduction bars to an angle ?. Vertical members are fixed to an outer perimeter of each of the plurality of laminates of the lamination stack. Hoop members are fixed to each of the plurality of vertical members and an outer edge of each of the plurality of conduction bars. A conduction ring is fixed on each of the ends of the lamination stack. An outer perimeter of the lamination stack is machined to remove the plurality of vertical members and the plurality of hoop members from the lamination stack.

Abstract: A partial discharge calibration standard apparatus may include a first and second rigid members defining respective first and second facing surfaces. An electrically insulating material may be disposed between the facing surfaces. The apparatus may further include a pressure member maintaining the rigid members together, thereby fixing the first and second facing surfaces in a substantially parallel spaced relation across the insulating material such that a partial discharge threshold magnitude for an electrical potential difference between the first and second facing surfaces is determined.

Abstract: A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Abstract: A method for manufacturing a stator includes the steps of: (1) providing a stator core module having a first stator fixture disposed on a first side of the stator core module, the first stator fixture is configured to support a first set of stator core junction portions in a fixed position; (2) providing a first crown module having a set of first crown junction portions and a first crown fixture to support the first set of first crown junction portions; (3) aligning the first stator fixture with the first crown fixture so that the first set of stator core junction portions are aligned with the first crown junction portions; and (4) joining the first set of stator core junction portions with the first crown junction portions.

Abstract: A rotor for an induction motor includes a first shorting end ring, a second shorting end ring, and a plurality of conductor bars. Each conductor bar has a first end and a second end and is coated with an electrically conductive material. The first end of each conductor bar is in electrical and mechanical contact with the first shorting end ring, and the second end of each conductor bar is in electrical and mechanical contact with the second shorting end ring. The conductive material is disposed between each conductor bar and the respective shorting end rings.

Abstract: A method for manufacturing an induction rotor includes placing a lamination stack into a fixture in which the first end of the lamination stack is rotated in an opposite rotational direction from the second end of the lamination stack to skew the conduction bars to an angle ?. Vertical members are fixed to an outer perimeter of each of the plurality of laminates of the lamination stack. Hoop members are fixed to each of the plurality of vertical members and an outer edge of each of the plurality of conduction bars. A conduction ring is fixed on each of the ends of the lamination stack. An outer perimeter of the lamination stack is machined to remove the plurality of vertical members and the plurality of hoop members from the lamination stack.

Abstract: A method of forming a weld interface between a first workpiece and a second workpiece includes arranging a reactive braze material at a first joining surface of the first workpiece. The reactive material is selected to react upon being heated to a temperature below the solidus temperature of the first and second workpieces to form a liquid-containing reaction product. Furthermore, an assembly is prepared of the first workpiece and the second workpiece with the first joining surface of the first workpiece and a second joining surface of the second workpiece separated by the reactive material. The second workpiece is then heated with a first laser beam following a first path and with a second laser beam following a second path.

Abstract: A method of forming a rotor includes isolating a bridge area of an electrical steel lamination. The bridge area is disposed between a first portion of the electrical steel lamination and a second portion of the electrical steel lamination that is adjacent to the first portion. Each of the first portion, the second portion, and the bridge area has an initial hardness, and the electrical steel lamination has an initial magnetic permeability. After isolating, the method includes hardening only the bridge area so that the bridge area has a treated hardness that is greater than the initial hardness. Concurrent to hardening, the method includes decreasing the initial magnetic permeability at only the bridge area.

Abstract: A method of joining together adjacent overlapping copper workpieces by way of resistance spot welding involves providing a workpiece stack-up that includes a first copper workpiece and a second copper workpiece that lies adjacent to the first copper workpiece. The faying surface of the first copper workpiece includes a projection that ascends beyond a surrounding base surface of the faying surface and makes contact, either directly or indirectly, with an opposed faying surface of the second copper workpiece. Once provided, a compressive force is applied against the first and second copper workpieces and an electric current is passed momentarily through the first and second copper workpieces. The electric current initially flows through the projection to generate and concentrate heat within the projection prior to the projection collapsing. This concentrated heat surge allows a metallurgical joint to be established between the first and second copper workpieces.

Abstract: An electronic transmission range selection (ETRS) system for a motor vehicle transmission includes an ETRS housing disposed on the transmission, the ETRS housing having a magnetic field sensor in communication with a transmission controller; and a magnetic field source including a magnet component and a high magnetic permeability component. The magnetic field source disposed on a transmission selector shaft, the magnetic field source detectable by the magnetic field sensor at a plurality of predetermined positions along a movement path of the transmission selector shaft; and the magnetic field sensor detecting magnetic flux generated by the magnetic field source, and communicating magnetic field source position information to the controller. The high magnetic permeability component homogenizes the magnetic flux generated by the magnet component and the controller generates an electronic transmission mode signal based on the magnetic field source position information.

Abstract: Additive manufacturing systems, area scanning laser systems, and methods for performing an additive manufacturing process are provided. An exemplary additive manufacturing system includes a laser generation device for producing a laser beam. Further, the additive manufacturing system includes an optic element for forming a first portion of the laser beam with a first polarization and a second portion of the laser beam with a second polarization different from the first polarization to encode an image in the laser beam. Also, the additive manufacturing system includes a selective beam separator configured to direct the first portion of the laser beam onto a material to be sintered or melted. The additive manufacturing system includes a recycling system for receiving the second portion of the laser beam.

Abstract: A method of joining a first metal workpiece substrate and a second metal workpiece substrate by way of reaction metallurgical joining involves passing a pulsating DC electrical current through the metal workpiece substrates and a reaction material disposed between confronting faying surfaces of the workpiece substrates. The electrical current comprises a plurality of current pulses that generally increase in applied current level.

Abstract: A method of joining together adjacent overlapping copper workpieces by way of resistance spot welding involves providing a workpiece stack-up that includes a first copper workpiece and a second copper workpiece that lies adjacent to the first copper workpiece. The faying surface of the first copper workpiece includes a projection that ascends beyond a surrounding base surface of the faying surface and makes contact, either directly or indirectly, with an opposed faying surface of the second copper workpiece. Once provided, a compressive force is applied against the first and second copper workpieces and an electric current is passed momentarily through the first and second copper workpieces. The electric current initially flows through the projection to generate and concentrate heat within the projection prior to the projection collapsing. This concentrated heat surge allows a metallurgical joint to be established between the first and second copper workpieces.

Abstract: An aperture plate for a welding apparatus includes a body defining an aperture. The body of the aperture plate includes a first end and a second end that is opposite the first end. In addition, the body includes a first surface intersecting the first and second ends. Moreover, the body includes a second surface formed opposite the first surface. The second surface is nonparallel to the first surface.

Abstract: An arc welding/brazing process is disclosed that is useful to join together a first copper piece and a second copper piece without damaging more heat-sensitive materials that may be located nearby is disclosed. The arc welding/brazing process includes using a non-consumable electrode wire, which electrically communicates with a weld control in a straight polarity orientation, to strike an arc across a gap established between a leading tip end of the electrode wire and the first copper piece. The current that flows through the arc when the arc is established heats the first copper piece such that the first copper piece becomes joined to a second copper piece. The joint between the first copper piece and the second copper piece may be an autogenous weld joint or a braze joint.

Abstract: A rotor for an induction motor includes a first shorting end ring, a second shorting end ring, and a plurality of conductor bars. Each conductor bar has a first end and a second end and is coated with an electrically conductive material. The first end of each conductor bar is in electrical and mechanical contact with the first shorting end ring, and the second end of each conductor bar is in electrical and mechanical contact with the second shorting end ring. The conductive material is disposed between each conductor bar and the respective shorting end rings.