Interfitting Or Claw Tooth Rotors Patents (Class 310/263)
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Patent number: 5786652Abstract: The invention relates to a 2N pole claw rotor comprising a first magnetic material part, comprising an axial hub having a free end, and an end provided with N axially-extending claws that are peripherally localized, uniformly distributed, and together define a bezel; a second magnetic material part of polarity opposite to the polarity of the first magnetic material part, having the same shape as the first magnetic material part, and disposed facing the first magnetic material part, each claw of the second magnetic material part being disposed between two claws of the first magnetic material part, and vice versa; non-magnetic spacers interposed between the free ends of the claws and the end walls of the bezels of the facing parts; and non-magnetic rotor-cowling means.Type: GrantFiled: January 9, 1997Date of Patent: July 28, 1998Assignee: GEC Alsthom Moteurs SAInventors: Alain Gueraud, Jean-Charles Mercier, Andre Masson
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Patent number: 5780953Abstract: In an on-vehicle alternator, both the magnetic flux variation frequency and maximum flux density are decreased sufficiently to thereby decrease the internal iron loss and thereby realize an increase in the current generation efficiency. The on-vehicle alternator comprises a rotor wherein magnetic pole cores that are polarized by a rotor coil to alternately different polarities are circumferentially disposed on the outer periphery thereof at prescribed equi-angular intervals. A permanent magnet which is embedded within a resin-made retainer body is provided between the magnetic pole cores and has side faces, as viewed circumferentially, which are polarized respectively to the same polarities as those of adjacent respective magnetic pole cores to thereby vary the magnetic flux quantity directed toward stator coils so as to exhibit a circumferential gentle curve.Type: GrantFiled: June 5, 1996Date of Patent: July 14, 1998Assignee: Nippondenso Co., Ltd.Inventors: Atsushi Umeda, Norihito Tokura, Hirohide Sato, Makoto Taniguchi, Shin Kusase
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Patent number: 5757102Abstract: An object of the present invention is to provide a dynamoelectric machine that can be manufactured merely by adding simple work without the necessity of increasing the number of parts and that is characteristic of a minimized electromagnetic sound.Included are a pair of field cores 12 having a plurality of claw-like magnetic poles 12a on the outer circumference thereof and being arranged so that the claw-like magnetic poles 12a can alternately mesh with one another, a coil frame 14 caught in the pair of field cores 12, a field coil 13 wound about the coil frame 14, and varnish layers 18 interposed between the field cores 12 and coil frame.Type: GrantFiled: April 30, 1996Date of Patent: May 26, 1998Assignee: Mitsubishi Denki Kabushiki KaishaInventors: Katsumi Adachi, Kazunori Tanaka, Yoshihiro Shinosaka, Kyoko Kurusu
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Patent number: 5747913Abstract: A hybrid alternator has a rotor with a plurality of permanent magnets disposed between opposing claw-pole segment pole fingers. The magnets are radially retained by the pole fingers during rotation. The magnets are supported during high speed rotation characterized by outward flexure of the pole fingers at surfaces inboard of extreme ends of the magnets thereby reducing load stresses on the magnet.Type: GrantFiled: December 3, 1996Date of Patent: May 5, 1998Assignee: General Motors CorporationInventors: Dale Alan Amlee, Michael Frank Matouka, Richard Allen Rausch, Keith Otipoby
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Patent number: 5726517Abstract: The invention relates to a magnetoelectric claw rotor of the type comprising parts made of magnetic material forming the poles of the rotor, and parts made of non-magnetic material for separating poles of opposite polarity, all confined in a common hollow cylindrical case of non-magnetic material.Type: GrantFiled: March 18, 1997Date of Patent: March 10, 1998Assignee: GEC Alsthom Moteurs SAInventors: Alain Gueraud, Jean-Charles Mercier
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Patent number: 5714822Abstract: A magnet wire having generally round cross section is taken out from a wire pack and formed by a forming roller mechanism into a polygonal shape in cross section to be wound on a bobbin tightly, thereby increasing the space factor of a coil. Then, magnet wire having round cross section is wound in a portion where pressure may be applied from the outside. Since the round wire is easy to move and able to dodge the pressure, a reliable coil of a high space factor can be obtained.Type: GrantFiled: May 16, 1996Date of Patent: February 3, 1998Assignee: Nippondenso Co., Ltd.Inventors: Yusuke Kawano, Mitsuyuki Hayashi
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Patent number: 5708318Abstract: An AC generator includes a rotor composed of a pair of generally cylindrical pole cores each having a plurality of claw poles. The claw poles have first and second chamfers disposed respectively on both leading and trailing sides thereof. A ratio b/a between a circumferential width a of the first chamfer and a circumferential width b of the second chamfer is in a range from 2.5 to 5.0, and a chamfered angle .theta.r.degree. of the second chamfer is in a range from 60.degree. to 75.degree..Type: GrantFiled: February 7, 1997Date of Patent: January 13, 1998Assignee: Denso CorporationInventor: Kiyoshi Fudono
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Patent number: 5708316Abstract: In an alternator for a vehicle having field coils for generating rotating magnetic field and stator coils for generating alternating current voltages in response to the rotating magnetic field, each of three stator coils are wound on only one of three stator teeth provided equi-angularly in a two pole-pitch of the rotor so that coil ends of the stator coils exposed outside the stator teeth do not cross each other. Thus, all the coil ends are cooled equally by the cooling air and a temperature rise of the stator coils is minimized. In order to reduce magnetic noise the stator coils are grouped. The first group of coils are provided in contact with a stator core and a second group of coils. The first and second group of coils are shifted from each other by .pi./3 radian in electrical angle.Type: GrantFiled: July 16, 1996Date of Patent: January 13, 1998Assignee: Nippondenso Co., Ltd.Inventor: Hiroshi Ishida
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Patent number: 5705865Abstract: A rotary electric machine that controls fluid pressure and loss of cooling air, increases the cooling air flow rate, and is able to favorably cool the end of a coil with little regard to the positional relationship between the centrifugal blades and the end of the stator coil, is disclosed. A cooling fan of such a rotary electric machine includes centrifugal blades having deflecting blades disposed therebetween, which are mounted so as to incline towards an inside of the axial direction. The centrifugal blades and the deflecting blades are integrally formed. For this reason, the cooling air accelerates at areas between the individual blades in the centrifugal direction and is separated into two flows, one in the direction of inside portions and one in the direction of outside portions of the end of a stator coil. The end of the stator coil is cooled favorably.Type: GrantFiled: April 19, 1996Date of Patent: January 6, 1998Assignee: Nippondenso Co., Ltd.Inventors: Hiroshi Ishida, Shin Kusase
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Patent number: 5693992Abstract: A cooling fan for an AC generator of a motor vehicle implemented in light weight and having a high cooling capability with generation of noise being suppressed to a minimum. The cooling fan is composed of a metallic base plate, blade members of a synthetic resin material fitted on elongated core members each having a small width and formed by bending projecting portions of the base plate and a fan guide fixedly secured to the core members at top end thereof by welding.Type: GrantFiled: December 20, 1994Date of Patent: December 2, 1997Assignee: Mitsubishi Denki Kabushiki KaishaInventors: Kyoko Kurusu, Katsumi Adachi
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Patent number: 5663605Abstract: In several embodiments of the present invention, an alternator is disclosed. The alternator includes a rotor having both wound-field and permanent magnet poles. The wound-field and permanent magnet poles are disposed about the circumference of the rotor.Type: GrantFiled: May 3, 1995Date of Patent: September 2, 1997Assignee: Ford Motor CompanyInventors: Paul Michael Evans, Roy David Schultz
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Patent number: 5656922Abstract: A vehicle based AC power system includes a specialized high efficiency vehicle alternator capable of supplying its maximum rated DC output current, even when being driven by an idling vehicle engine, to power a DC to AC inverter and provide maximum rated AC power at any engine speed. The alternator is preferably a wound field and permanent magnet hybrid alternator employing a three state bridge-type voltage regulator. An electrical load monitor electrically connected to monitor the electrical load on the alternator and a transmitter and receiver are used to remotely signal a user whenever there is an excessive load on the system.Type: GrantFiled: December 14, 1994Date of Patent: August 12, 1997Assignee: Ecoair Corp.Inventors: William J. LaVelle, Charles D. Syverson, William P. Curtiss
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Patent number: 5607525Abstract: End segments of a Lundell-type rotor for an AC generator, wherein the base and the teeth portions thereof are compaction molded separately and subsequently joined together and sintered.Type: GrantFiled: September 19, 1994Date of Patent: March 4, 1997Assignee: General Motors CorporationInventor: David E. Gay
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Patent number: 5578885Abstract: An alternator has a rotor with a plurality of permanent magnets disposed between opposing claw pole members and a field coil. The plurality of permanent magnets are secured to at least one ring-shaped carrier which surrounds the field coil and locates the magnets into appropriate positions between the fingers of the claw pole members.Type: GrantFiled: December 22, 1994Date of Patent: November 26, 1996Assignee: General Motors CorporationInventors: Stephen A. Alford, Richard A. Rausch, Gilbert E. Shirk
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Patent number: 5574324Abstract: Plural thin plate projecting portions are integrally and projectingly provided on an outer peripheral portion of a side plate member of a bobbin. Each of the thin plate projecting portions comprises a circumferential rib, a slit portion and a reinforcement rib. The circumferential rib is provided on an outer peripheral face of the thin plate projecting portion of the bobbin and then a gap is formed between a claw-shaped magnetic pole of a rotor core and the thin plate projecting portion. A varnish material etc. is caused to adhere to and harden in this gap. By filling a root portion of the claw-shape magnetic pole of the rotor core with varnish material, the resonance vibration in the rotor core can be restrained. As a result, an alternating current generator for use in a vehicle having the small magnetic noise can be obtained.Type: GrantFiled: March 1, 1995Date of Patent: November 12, 1996Assignees: Hitachi, Ltd., Hitachi Automotive Engineering Co., Ltd.Inventors: Makoto Hirama, Kenji Ishihara, Susumu Sasaki, Yoshiaki Honda
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Patent number: 5561334Abstract: A rotary electric machine that controls fluid pressure and loss of cooling air, increases the cooling air flow rate, and is able to favorably cool the end of a coil with little regard to the positional relationship between the centrifugal blades and the end of the stator coil, is disclosed. A cooling fan of such a rotary electric machine includes centrifugal blades having deflecting blades disposed therebetween, which are mounted so as to incline towards an inside of the axial direction. The centrifugal blades and the deflecting blades are integrally formed. For this reason, the cooling air accelerates at areas between the individual blades in the centrifugal direction and is separated into two flows, one in the direction of inside portions and one in the direction of outside portions of the end of a stator coil. The end of the stator coil is cooled favorably.Type: GrantFiled: July 26, 1994Date of Patent: October 1, 1996Assignee: Nippondenso Co., Ltd.Inventors: Hiroshi Ishida, Shin Kusase
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Patent number: 5552653Abstract: In an electric motor, in order to simplify the structure and to remarkably improve the T/N characteristic value, yoke plates mounted on a field magnet are so shaped that the total magnetic flux of the field magnet is collectively extended to the iron core of the armature with its direction repeatedly reversed. That is, in the motor, the multi-polarization is substantially obtained by designing it in such a manner that the total magnetic flux of the field magnet is not dispersed but concentrated. Hence, in the motor, unlike a conventional motor, the field magnet is not subjected to multi-polar magnetization, and the armature side is simplified in structure, and the magnetic flux from the field magnet is maximaly utilized at all times, so that the number of magnetic poles and the effective flux .PHI. are both increased.Type: GrantFiled: December 22, 1993Date of Patent: September 3, 1996Assignee: Kabushiki Kaisha Sankyo Seiki SeisakushoInventor: Tamotsu Nose
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Patent number: 5552651Abstract: An automotive alternator has a rotor including a first single coil Lundell portion and a second permanent magnet portion. Permanent magnet poles are axially aligned in spaced adjacency with the fingers of the magnetic members of the Lundell portion of the machine. The current through the field coil of the Lundell portion is controllable in magnitude and direction to control the output of the machine.Type: GrantFiled: July 3, 1995Date of Patent: September 3, 1996Assignee: General Motors CorporationInventor: Thomas A. Radomski
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Patent number: 5551143Abstract: A rotor shaft for electro-dynamic machinery such as a motor vehicle alternator includes a cold-headed slot through a bearing land formed on the shaft. The slot extends axially through a bearing land and either extends radially through a collar portion adjacent the bearing land, or communicates with a radially aligned shaped conductor on a slip ring. Preferably, two diametrically opposed slots are formed, and the slots provide a means for aligning the wires, for example, prior to encapsulation of the rotor by injection molding, while positioning the leads for engagement with the winding terminals and with the conductor rings on the slip ring bushing. Preferably, the shaft is made by a sequential set of cold heading steps which avoid deformation or uneven formation of the groove. A cold headed shaft formed without a collar is preferably through-fed in a single direction through one or more machining stations for production efficiency.Type: GrantFiled: October 21, 1994Date of Patent: September 3, 1996Assignee: Ford Motor CompanyInventors: Joseph E. Saval, Timothy J. Brunetz
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Patent number: 5548885Abstract: A method of forming a stator for a stepping motor, including the steps of forming comb teeth by cutting a flat section of a plate having a cylindrical section around the flat section and bending the comb teeth up to a first angle. Next, the comb teeth are bent up to a second angle larger than the first angle and the thickness of the comb teeth is reduced so as to render uniform the thickness of all the comb teeth. Then, the cylindrical section is subjected to a drawing process at least one time. Finally, the comb teeth are bent up to a right angle. As a result, the occurrence of cambers in the comb teeth is eliminated and the comb teeth are not inclined in the peripheral direction. Also, the accuracy with which the comb teeth are bent to a right angle can be improved thereby.Type: GrantFiled: March 28, 1994Date of Patent: August 27, 1996Assignees: Canon Seiki Kabushiki Kaisha, Canon Kabushiki KaishaInventor: Takahisa Yamada
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Patent number: 5543677Abstract: In a slipring-less generator having magnetic coupling rotors embodied in claw pole fashion, it is proposed that the two additional air gaps, which are embodied by annular magnetic flux guide elements, are extended obliquely at an angle to the longitudinal axis of the generator and extend at least in part above or below the field winding, so that with a corresponding enlargement of the further two air gaps present in addition to the working air gap and a resultant reduction of magnetic voltage in these air gaps, either higher power or a shorter structural length with a corresponding weight reduction is obtained.Type: GrantFiled: September 19, 1994Date of Patent: August 6, 1996Assignee: Robert Bosch GmbHInventor: Bernhard Fakler
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Patent number: 5543676Abstract: In one embodiment of the present invention, a rotor of a "claw pole" alternator includes first and second pole pieces with intermeshing fingers. Magnetic inserts are provided made preferably of permanent magnet material. Each insert extends under the end of a pole finger of the rotor and has two surfaces which face radially outward from the rotor. The resulting design provides improved power output and reduced acoustic noise when compared with conventional alternators, in a design which is durable and amenable to mass production.Type: GrantFiled: March 16, 1995Date of Patent: August 6, 1996Assignee: Ford Motor CompanyInventors: Michael T. York, Richard K. Harris
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Patent number: 5539265Abstract: An alternator rotor assembly comprises two "claw pole" pole pieces and a field coil assembly mounted between the pole pieces for rotation therewith. The field coil assembly comprises a bobbin and a coil of wire wound around the body of the bobbin. The bobbin further comprises two walls extending radially away from the center of the bobbin, between which the coil wire is wound. Projecting from the walls are flaps which extend radially outward. The flaps are designed to be bent over by the pole fingers as the rotor assembly is assembled. When so bent over, the flaps help retain the coil wire on the bobbin and help prevent short-circuiting of the coil wire to the inner radius defined by the pole fingers. The ends of the flaps have notches. In one embodiment of the invention, the notches are adapted to allow insertion of the ends of the pole fingers. The notches in the flaps help assure alignment of the flaps and the pole fingers as assembly is begun.Type: GrantFiled: October 11, 1994Date of Patent: July 23, 1996Assignee: Ford Motor CompanyInventors: Richard K. Harris, Michael T. York
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Patent number: 5536987Abstract: An alternating current generator for a motor vehicle includes magnet type field cores, i.e., field cores with claw poles on which permanent magnets are interposed in the spaces between the claw poles, where the generator has a ratio of number of claw poles/outside diameter of the field core that allows generation of a large output current. The alternating current generator includes permanent magnets disposed in spaces between peripherally adjacent claws which reduce the magnetic flux leakage caused by the field coil occurring in the spaces. When a residual magnetic flux density higher than 0.25 tesla is applied in advance in a direction that reduces magnetic flux, a large output current is obtained when the above-noted ratio is in the range of from about 1.6.times.10.sup.-1 to 2.0.times.10.sup.-1 (1/mm).Type: GrantFiled: November 23, 1994Date of Patent: July 16, 1996Assignee: Nippondenso Co., Ltd.Inventors: Seiji Hayashi, Atsushi Umeda, Shin Kusase
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Patent number: 5530305Abstract: Disclosed herein is an engine assembly comprising an engine block, a crankshaft rotatably mounted in the engine block and having an end and an axis, a flywheel fixed to the end of the crankshaft and including a first flux plate including a plurality of angularly spaced pole pieces extending axially away from the end of the crankshaft, a second flux plate axially spaced from the first flux plate and including a plurality of angularly spaced pole pieces extending toward the first flux plate and being spaced from and inter-digitated between the pole pieces of the first flux plate, a core extending axially between the first and second flux plates, a coil located in surrounding relation to the core and radially inwardly of the pole pieces and between the first and second flux plates, and a stator coil stationarily mounted on the engine block in outward, radially adjacent relation to the pole pieces, and slip ring means mounted on the flywheel and on the engine block and connected to the coil for energization thereType: GrantFiled: January 13, 1994Date of Patent: June 25, 1996Assignee: Outboard Marine CorporationInventors: William R. Krueger, David W. Windstein, Paul W. Breckenfeld, James R. DeRam, Gregory J. Binversie
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Patent number: 5526560Abstract: A method for manufacturing a stator of a stepping motor comprises the steps of carrying out a half-pierce and push-back process to a frame plate to make an area in which comb teeth are to be formed and an area to be blanked out readily separable, carrying out a blanking process to separate the blanked out area from the comb teeth, and bending the comb teeth to a predetermined angle and collapsing the comb teeth to make the thicknesses of the comb teeth uniform. The comb teeth are then bent at right angles to an outer periphery of the frame plate.Type: GrantFiled: March 1, 1994Date of Patent: June 18, 1996Assignees: Canon Seiki Kabushiki Kaisha, Canon Kabushiki KaishaInventor: Yoku Tsuruya
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Patent number: 5519277Abstract: A rotor assembly for an electrical machine includes two pole pieces with intermeshing pole fingers. Disposed between the pole pieces is a silencer assembly with silencer portions at least partially filling the gaps between adjacent pairs of intermeshed pole fingers. The silencer portions have projections which cooperate with lateral surfaces of the pole fingers to limit outward radial movement of the silencer portions.Type: GrantFiled: December 27, 1994Date of Patent: May 21, 1996Assignee: Ford Motor CompanyInventors: Michael T. York, Richard K. Harris
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Patent number: 5483116Abstract: The present invention prevents the degradation of the power generating efficiency of an alternating current generator by preventing the expansion of an air gap formed between pole cores and a stator core, achieves low-noise operation by preventing generation of high-frequency impact magnetic noise, and makes it possible to relieve strains applied on a magnet holder. The present invention utilizes sixteen magnets, each of which fits between two of sixteen claw-like magnetic poles formed on the outer periphery of Lundell-type pole cores, which rotates integrally with a shaft. The magnets are caught and stopped by a magnet holder which has been formed by interconnecting zig-zagging segments and has elasticity as a whole. Here, the permanent magnets are held by the magnet holder so that the magnet holder does not protrude towards the rotor side from the outer peripheral face of the Lundell-type pole cores and the contacting faces of the magnet holder contact the outer faces of the permanent magnets.Type: GrantFiled: August 30, 1994Date of Patent: January 9, 1996Assignee: Nippondenso Co., Ltd.Inventors: Shin Kusase, Atsushi Umeda, Saburo Hukaya, Noriyasu Inomata, Hitoshi Irie, Hiroshi Ishida
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Patent number: 5444321Abstract: Object of the present invention is to provide an induction alternating current generator on vehicle and a method for generating alternating current in a generator on vehicle, which improve the efficiency of the generator by increasing magnetic flux permeating a stator core.Second electromagnetic exciting means for generating magnetic field in the direction of repelling the leak magnetic flux between neighboring claw poles, are provided in the spaces formed by the neighboring claw poles engaging each other at a gap and first electromagnetic exciting means provided inside a pair of the rotor cores of the induction alternating current generator on vehicle.Type: GrantFiled: September 1, 1993Date of Patent: August 22, 1995Assignee: Hitachi, Ltd.Inventors: Yoshiaki Honda, Hitoshi Minorikawa, Hideaki Kamohara
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Patent number: 5440185Abstract: The brushless DC motor comprises at least one multi-pole composite magnet which functions as a rotor, at least one stator member which determines the angular position of this rotor, means for positioning the rotor(s) and the stator member(s) on a common axis, a sensing device for determining the position of the composite magnet relative to the stator member(s), and means for determining the magnetic configuration on the stator member. The composite magnet comprises two sections, each section having a plurality of projections and apertures. The projections and apertures on a first section mate with the apertures and projections, respectively, on the second section. The first and second sections are magnetized in opposite axial directions. In one embodiment, each stator member has a plurality of pole pieces which are positioned in operative relation to the composite magnet. Two windings are formed on each stator member.Type: GrantFiled: October 9, 1992Date of Patent: August 8, 1995Inventor: Elmer C. Allwine, Jr.
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Patent number: 5437090Abstract: A method of making a rotor of an inductor type alternating current generator formed by connecting opposedly and alternately disposed first and second claws 3a, 3b of first and second inductors excited by an excitation coil 8 in different polarities through a nonmagnetic ring 3c. Contacting portions 22, 23 of the first and second claws and the nonmagnetic ring are connected by a welding means from inner sides of the claws and in a direction inclined to an axial direction by a predetermined angle.Type: GrantFiled: February 25, 1994Date of Patent: August 1, 1995Assignee: Mitsubishi Denki Kabushiki KaishaInventors: Yukio Sakane, Yutaka Kitamura
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Patent number: 5434461Abstract: A drive has a hub with first and second end portions and a shoulder located thereon. An armature and sheave assembly is located on bearings on the hub first end portion. The armature forms a cavity for receiving an electromagnet, which abuts against the shoulder. Slip rings are coupled to the electromagnet by way of a fan and a slip ring shaft. The slip rings, which are adjacent to the second end of the hub, can be of a small diameter to extend brush life. In addition, the same size slip rings can be used on different sizes of the drive. Two piece brush holders are provided for each brush. Each brush holder can be disassembled into its respective pieces for cleaning. The brush holders and slip rings can be protected from the environment by a cover. In another embodiment, a brushless drive has a coil mounted to bearings by way of a coil mount. The bearings are located on a hub. The coil mount is anchored to a fixed object.Type: GrantFiled: April 30, 1993Date of Patent: July 18, 1995Inventor: Paul D. Boggs, III
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Patent number: 5424599Abstract: The alternator has an annular stationary stator and a rotor concentrically located therein with two, three phase delta windings wound on the stator core. In one embodiment, the two three phase windings are connected together in series for use with two batteries for supplying 12 and/or 24 volts D.C. In this embodiment the two three phase windings are the same and are wound on the segments of the core such that coils of the same number of turns are wound around the same groups of segments. In another embodiment, the two three phase windings are connected together in parallel for use with one battery for supplying 12 volts D.C. In this embodiment, the two three phase windings are different and are wound on the segments of the core such that coils of different turns are wound around the same groups of segments.Type: GrantFiled: February 26, 1993Date of Patent: June 13, 1995Inventor: Leburn W. Stroud
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Patent number: 5382862Abstract: A rotor for an alternating current generator of the Lundell type. The rotor shaft carries two segments which have interleaved pole teeth. The rotor has a core member and a field coil disposed about the core member. The segments and/or core member are formed of compressed powder iron particles having a particle size in a range of about 10 to 250 microns. In the manufacture of the core and/or segments the iron powder particles are coated with a thermoplastic material and this thermoplastic coated iron particle material is compacted in the molding dies of a press. After compaction to the desired shape, the part is sintered at a temperature of about 2050.degree. F. to burn-off the thermoplastic material that coated the iron particles.Type: GrantFiled: November 22, 1993Date of Patent: January 17, 1995Assignee: General Motors CorporationInventors: Robert W. Ward, Sam B. Parker, William E. Boys
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Patent number: 5361011Abstract: A rotor for an electrical machine comprises a bobbin, a winding, and two pole pieces. The winding comprises a wire wound around the outer surface of the bobbin. At least one flat on the outer surface of the bobbin is imparted on the winding, mechanically locking the winding to the bobbin. The bobbin is concentrically disposed over hubs on the two pole pieces, the bobbin and the hubs having complementary flats which only allow assembly of the bobbin and the hubs when the flats are aligned. A method for producing a rotor comprises providing a bobbin with at least one flat on its outer surface and at least one flat on its inner surface; winding wire around the outer surface of the bobbin to create a winding with at least one flat in it; providing two pole pieces with hubs with complementary flats to the at least one flat on the inner surface of the bobbin; aligning the flats on the hubs and on the inner surface of the bobbin; and inserting the hubs into the bobbin.Type: GrantFiled: December 6, 1993Date of Patent: November 1, 1994Assignee: Ford Motor CompanyInventor: Michael T. York
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Patent number: 5329199Abstract: A molded rotor assembly (20) including at least one molded fan (28), a method for making the same, and a vehicle alternator (160) using the molded rotor assembly (20) are disclosed. The rotor assembly (20) includes first and second pole pieces (24,26) aligned along a longitudinal axis (40) defining a region (122) between the pole pieces (24,26). Each pole piece (24,26) has an outboard axial face (69,71). At least one molded fan (28) is integrally molded to one of the axial outboard faces (69) of a pole piece (24). Preferably, a molded insert (22) is molded in the region (122) between the pole pieces (24,26) and is integral with the molded fan (28) to secure the molded fan (28) to the pole piece (24). Alternatively, anchoring recesses (241,245) are formed in an outboard face of a pole piece (224) with a molded fan (228) having anchoring portions (249,251) secured within the recesses (241,245) to retain the fan (228) to the outboard axial face.Type: GrantFiled: November 23, 1992Date of Patent: July 12, 1994Assignee: Ford Motor CompanyInventors: Steven J. Yockey, Gregory A. Ritchie, Joseph E. Saval, Eric D. Bramson
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Patent number: 5325003Abstract: A molded rotor assembly (20) for a vehicle alternator and method for making the same are disclosed. The rotor assembly includes first and second pole pieces (24,26) aligned along a longitudinal axis (40), the pair of pole pieces (24,26) defining a region therebetween. A coil wire (46) is located in the region. The pole pieces (24,26) and a slip ring assembly (36) are mounted on a rotor shaft (38). The slip ring assembly (36) has a pair of slip rings (102,104) connected to a pair of terminals (96,98) which are attached to respective free ends of the coil wire (46) to form a pair of connections (126,128). A molded insert (22) is injection molded filling the region between the pole pieces (24,26) thereby encapsulating the connections (126,128) and the coil wire (96) and forming a smooth cylindrical periphery on the rotor assembly (20).Type: GrantFiled: November 23, 1992Date of Patent: June 28, 1994Assignee: Ford Motor CompanyInventors: Joseph E. Saval, Steven J. Yockey, Gregory A. Ritchie, Eric D. Bramson
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Patent number: 5306977Abstract: A rotor for an alternator mounted on a vehicle comprises first and second claw-pole members formed of magnetic material and mounted on a shaft rotatable about an axis. The first and second claw-pole members have at least one first axially extending claw section and at least one second axially extending claw section respectively. The at least one first and second axially extending claw sections have a first side face and a second side face respectively. A field coil is disposed between the first and second claw-pole members. A permanent magnet is disposed between the first and said second side faces and is polarized in a direction which prevents magnetic flux leakage between the at least one first and second axially extending claw sections. The rotor has a space formed between the permanent magnet and at least one of the first and second side faces.Type: GrantFiled: August 7, 1992Date of Patent: April 26, 1994Assignee: Nippondenso Co., Ltd.Inventor: Seiji Hayashi
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Patent number: 5270605Abstract: A three-phase alternator for a motor vehicle has a rotor consisting of two pole wheels, each comprising a radial plate and a plurality of projecting teeth. Each tooth has an outer surface and two lateral surfaces, the outer surface being joined to a rear face of the radial plate through an inclined surface. Each tooth is formed with at least one antinoise chamfer adjacent to the outer surface, lateral surface, and inclined surface of the tooth, and adjacent also to the rear face, the antinoise chamfer being inclined by a different angle from that of each of these surfaces to which it is adjacent.Type: GrantFiled: May 21, 1992Date of Patent: December 14, 1993Assignee: Valeo Equipements Electriques MoteurInventors: Philippe Lefrancois, Pascal Couvert
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Patent number: 5270604Abstract: A tandem Coil armature in which a pair of spaced-apart field coils [91,92] are wound on bobbins [12,14] mounted within a set of magnetic core pieces [16,18,20,22]. Two L-shaped conductors [27,28] pass through passageways through the core pieces and connect the windings to slip-rings [72,74]. Insulated conductor carriers [31,32,37,38] sized to mate with passageways and recesses in the core pieces support the L-shaped conductors and electrically insulate them from the magnetic core piece material. The core pieces are mounted for rotation with the rotor shaft [10] and include interleaved claws at their periphery which form the rotors magnetic poles.Type: GrantFiled: May 21, 1992Date of Patent: December 14, 1993Assignee: Ford Motor CompanyInventors: Robert J. Sandel, Arthur J. Gajewski, James E. Caldwell
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Patent number: 5254896Abstract: A rotor for an alternating current generator of a type that has two pole segments provided with interleaved pole teeth and a core disposed between the segments that carries a field coil. The shaft of the rotor carries a slip ring assembly having two metallic slip rings. A ball bearing is disposed between one of the pole segments and the slip ring assembly. A portion of the shaft that is located inside of the inner race of the ball bearing has a pair of slots and wires for connecting the field coil to the slip rings are located in the slots and inside the inner race of the bearing. The electrical connections between the ends of the field coil and the slip rings includes wires that are twisted together to form twisted wire portions. The twisted wire portions are locked or fixed to a fan that is formed of thermoplastic material by material of the fan that completely encircles portions of the twisted wire portions.Type: GrantFiled: November 20, 1992Date of Patent: October 19, 1993Assignee: General Motors CorporationInventors: Michael D. Bradfield, Jorge E. Silva, Thomas R. Sowash
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Patent number: 5237232Abstract: A rotor for an AC generator includes first and second iron cores which function as magnetic poles for the rotor and which are fixed to a shaft. A plurality of magnetic teeth project from the circumference of each iron core at a position where the iron cores contact each other to form troughs between the magnetic teeth. Each trough between the magnetic teeth is V-shaped, so that the weight of the rotor is reduced. Furthermore, each iron core has a ring recess portion at an outer end surface of the iron core and around the axis thereof.Type: GrantFiled: June 23, 1992Date of Patent: August 17, 1993Assignee: Mitsubishi Denki K.K.Inventor: Yutaka Kitamura
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Patent number: 5233255Abstract: The present invention of an AC generator for use in a vehicle in which front and rear brackets hold a stator there-between and support rotatably a rotor theirbetween inside the stator. A pair of magnetic pole cores mounted on the rotor has end surfaces and holds an exciting coil theirbetween. Two fans are mounted on the end surfaces, respectively, so as to produce cooling blow. wherein said magnetic pole cores are formed such that a height in a circumference direction thereof is greater than a length between said two surfaces to thereby increase an area thereof to be in contact with said exciting coil, so that the transfer and diffusion of the heat of the exciting coil to the magnetic pole can be performed.Type: GrantFiled: July 17, 1992Date of Patent: August 3, 1993Assignee: Mitsubishi Denki K.K.Inventors: Katsuhiko Kusumoto, Toshinori Tanaka
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Patent number: 5229672Abstract: In a method of adjusting the balance of the rotor of an AC generator which comprises a pair of magnetic pole cores with magnetic pole claws which are intertwined with each other, the amount and direction of unbalance of the rotor are detected, the amount of unbalance thus detected is divided into two components along the center lines of adjacent magnetic pole claws, a hole is drilled in the outer peripheral surface of the magnetic pole claw on which the larger of the components lies in such a manner that the hole is in alignment with the center line of the magnetic pole claw; and those operations are carried out repeatedly until the balance thus adjusted falls in a predetermined range of allowance, whereby the balance of the rotor is readily adjusted with high accuracy.Type: GrantFiled: June 10, 1992Date of Patent: July 20, 1993Assignee: Mitsubishi Denki K.K.Inventor: Yoshiyuki Iwaki
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Patent number: 5214335Abstract: A brush and slip ring apparatus for an alternating current generator. A brush assembly is secured to a rotor shaft of the generator to rotate therewith. The brush assembly includes two axially spaced brushes that are pivoted to a brush support that is secured to the shaft. When the shaft is rotated, the brushes move outwardly away from the shaft due to centrifugal force. The brushes respectively engage two axially spaced fixed slip rings that surround the brush assembly. The brushes are maintained engaged with the slip rings due to centrifugal forces developed by the pivotally mounted brushes. The brushes are connected to a field coil of the rotor of the generator.Type: GrantFiled: July 7, 1992Date of Patent: May 25, 1993Assignee: General Motors CorporationInventors: Gregory A. Phillips, Raymond Prater, Thomas C. Ruth
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Patent number: 5177391Abstract: An a.c. generator having a stator including an armature core and a polyphase output winding wound around the armature core. A plurality of rotors mounted on a rotary shaft to establish a first and a second field magnetic circuits are arranged in parallel with respect to the armature core. The first field magnetic circuit includes permanent magnets acting as a source of exciting magnetomotive force, while the second field magnetic circuit includes a field winding acting as a source of exciting magnetomotive force. The magnetic fluxes generated from the first and second field magnetic circuits penetrate the armature core inducing an output voltage across the polyphase output winding. The magnetic flux from the second field magnetic circuit is changed so as to increase or decrease the total magnetic flux penetrating the armature core thereby controlling the induced output voltage.Type: GrantFiled: May 22, 1992Date of Patent: January 5, 1993Assignee: Nippondenso Co., Ltd.Inventor: Shin Kusase
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Patent number: 5160864Abstract: Cooling of an alternator driven by an internal combustion engine wherein a field core of the alternator is composed of claw-type magnet poles and a cylindrical core such that an oil passage is formed in the regions where the cylindrical core and the rotor shaft oppose each other and where the cylindrical core and the claw-type magnetic poles oppose each other. The oil passage is communicated at its one end with an oil source outside the alternator so as to introduce an oil into the oil passage during operation of the alternator so that a centrifugal force is applied to the oil by the rotation of the rotary field core thereby spraying the oil in the form of vapor or mist onto the stator coil.Type: GrantFiled: March 30, 1989Date of Patent: November 3, 1992Assignee: Hitachi, Ltd.Inventor: Akihiro Saito
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Patent number: 5144178Abstract: A generator includes a permanent magnet rotor formed in a hollow rotating member rotatably mounted in a casing. A Randell rotor mounted adjacent to the permanent magnet rotor is rotated with the permanent magnet rotor. An armature coil is mounted in association with the permanent magnet rotor and the Randell (claw-tooth) rotor. A first bearing at one end of the casing supports one end of the hollow rotating member. A protruding retainer mounted on the other end of the casing carries a Randell field coil, and a second bearing is mounted on the retainer for supporting a hollow section of the hollow rotating member. The hollow rotating member is supported by the first bearing and a second bearing provided in the hollow section. The generator may be suitably applied to aerospace equipment, unmanned flying objects or to unmanned marine cruising objects.Type: GrantFiled: April 4, 1991Date of Patent: September 1, 1992Assignee: Tamagawa Seiki Kabushiki KaishaInventor: Tsuneo Sugiura
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Patent number: 5132581Abstract: In an AC generator having a plurality of claw-shaped magnetic pole portions in a rotor, a pair of projected portions which extend toward an outer circumference from both ends of boss portions on an outer circumference of a shaft are provided, and permanent magnets are also provided so as to abut against the projected portions so that magnetic flux is applied in the same direction as the magnetic flux applied to the projected portions when an electric current is applied to a field winding which is wound around the boss portions. With a magnetic path thus constructed, it is possible that the magnetic flux if permanent magnets is put on the magnetic flux produced by a field winding, thus applying much magnetic flux to the stator. As a result, the output per weight can be increased.Type: GrantFiled: February 22, 1991Date of Patent: July 21, 1992Assignee: Nippondenso Co., Ltd.Inventor: Shin Kusase
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Patent number: 5130595Abstract: Separate multiple flux paths for an electrical generator or motor are provided in a single rotor machine by axially mounting a plurality of pole pieces on the rotor shaft. Each pole piece includes a central disc portion having a plurality of radial pole-forming projections, with the projections of adjacent pole pieces rotated 180 electrical degrees, such that the pole-forming projections of every other pole piece have the same magnetic polarity. Provision of a plurality of separate magnetic flux paths increases the total flux attainable in a machine of given size and therefore improves the machine's output and efficiency.Type: GrantFiled: December 20, 1990Date of Patent: July 14, 1992Assignee: Chrysler CorporationInventor: Ram S. Arora