Abstract:
A dynamoelectric machine insulator includes, a body having a plurality of holes therethrough at least some of the plurality of holes being receptive of a lead such that a lead extending through each of the plurality of holes is electrically isolated from a lead extending through each of the other of the plurality of holes, and at least one channel in the body extending arcuately along a perimetrical extent of the body. The at least one channel configured and dimensioned to insulate at least one lead routed therein.
Abstract:
A stator and rotor assembly of a dynamoelectric machine wherein the stator core of the stator assembly includes a plurality of stator ring slots and the rotor assembly includes a plurality of rotor ring slots. The stator assembly further includes a conductor disposed in each stator ring slot having a plurality of full revolutions around the central axis of the stator core. The rotor assembly further including a rotor conductor disposed in each rotor ring slot having a plurality of full revolutions around the central axis of the rotor assembly. The stator core and rotor assembly both include tooth portions to direct the flux produced by the rotor conductor around the stator in the proper manner to induce the desired generated voltage in each stator conductor, thereby enabling each conductor to have the desired phase angle.
Abstract:
A method of forming a stator for an electric machine having a cascaded winding includes the steps of: providing a stator core having a plurality of circumferentially spaced and axially-extending core slots in a surface thereof, forming a plurality of A conductors and a plurality of B conductors, arranging the A and B conductors into a wire pack, rolling the wire pack into a cylindrical shape and inserting the wire pack within the stator core, and expanding the wire pack radially outward such that the wire pack is inserted within the slots of the stator core.
Abstract:
A method for making a stator assembly includes forming several continuous conductors with generally-coplanar parallel-spaced straight segments interconnected by end loop segments, as by winding each of several conductors on a peg board, and then pressing the conductors to form either one, two, or three generally-orthogonal “jogs” in a given end loop segment. The conductors are interpositioned with their straight segments staggered and with a first leg of each subsequent conductor's end loop segments generally overlying a second leg of the immediately-prior conductor's end loop segments, except for the two end loop segments following the first conductor's “nth” straight segment, and multiples thereof, where the stacking order is reversed (“n” being equal to the number of stator core slots divided by the number of conductors that will form a given winding layer). The resulting preform is inserted into the core slots over multiple revolutions to thereby obtain a multilayer cascaded stator winding with interleaved transitions.
Abstract:
A stator assembly for an alternator in accordance with the present invention includes a generally cylindrically-shaped stator core having a plurality of core slots formed along the inner surface thereof and defined by a radial depth and wherein a stator coil is disposed. The core slots thereby define a plurality of teeth therebetween, which are connected to the stator core by a yoke portion. The core slots are shaped and extend between a first and a second end of the stator core. A plurality of clips closely fit into one of said core slots for lining each respective core slot. The clips have a pair of extending leg members connected to a back end and forming an aperture therebetween. The clips are formed from a magnetically permeable material. A stator winding includes substantially straight wire segments that are received by the clips formed of substantially straight wire segments. The substantially straight wire segments of the stator winding and the clips are electrically insulated from one another. At least one of the extending leg members is bent towards the other leg member over a portion of the at least one row of substantially straight wire segments in the clips, narrowing the aperture between the extending leg members. Each of the plurality of clips and said substantially straight wire segments are each inserted into one of the plurality of core slots. Slits are added in these clips to reduce eddy current loss.
Abstract:
A stator for an electric machine includes a generally cylindrically-shaped stator core having a plurality of circumferentially spaced core slots. A stator winding includes a plurality of phases, each including at least a first filar and a second filar extending circumferentially around the stator core to form a plurality of layers. Each of the filars is a conductor having a plurality of slot segments disposed in the core slots. The slot segments are alternately connected at the first and second ends of the stator core by a plurality of end loop segments that may form a cascaded winding pattern. The plurality of filars of each phase alternating radial positions with one another within at least one end loop segment at discreet locations around the stator core such that the average radial position of the slot segments of the first filar conductors is substantially equal to that of the second filar.
Abstract:
A stator assembly for a dynamoelectric machine featuring a cascaded construction includes several conductors, each having a plurality of slot segments interconnected by plurality of end loop segments. The consecutive slot segments of a first conductor forms nearly all of a radially-outermost first layer of the stator winding, with the remaining portion of the radially-outermost winding layer being defined by a slot segment of a second conductor that is then inserted into the core to form nearly all of a second layer of the stator winding radially-inwardly of the first winding layer. The second winding layer is completed with an additional single slot segment of the first conductor.
Abstract:
A brush holder assembly for an alternator having a rotational axis includes a pair of brushes each having a contacting surface defining a width and a height, and each having a shunt wire extending laterally from the brush in the widthwise direction. The brush holder assembly includes a housing having first and second brush chambers, corresponding first and second wire cavities each defining a cavity height, and first and second slots respectively interposed between the corresponding chamber and cavity. The respective shunt wires extend through the first and second slots then through the first and second wire cavities. The cavity heights are each at least approximately 0.9 times the height of one of the brushes. The height of the first wire cavity is less than approximately 0.97 times ((A/2) plus B), wherein A is the brush height and B is the distance between the brushes.
Abstract:
Embodiments of the invention provide a starter machine that includes a motor operatively coupled to a first shaft and a pinion coupled to a second shaft. In some embodiments, a planetary gear drive system can be coupled to the first and the second shafts. The planetary gear drive system can include a planetary gear system and a first clutch being substantially adjacent to a second clutch. The planetary gear drive system can be configured and arranged so that when the first clutch is engaged, the motor can move the pinion at a first rotational speed. The planetary gear drive system is further configured so that when the second clutch is engaged, the motor can move the pinion at a second rotational speed. In some embodiments, the first rotational speed is a greater rotational speed than the second rotational speed.
Abstract:
An apparatus for loading stator windings into a stator core includes an arbor member including a body having a central axis and an outer diametric portion provided with a plurality of slots. An insertion element is rotatably mounted adjacent the arbor member. The insertion element includes a plurality of slot elements that are configured to register with the plurality of slots. A loading member is rotatably mounted adjacent the insertion element. The loading member includes a plurality of slot members that are configured to register with the plurality of slot elements. The loading member is selectively operated to receive a stator winding into one of the plurality of slot members and transfer the stator winding into one of the plurality of slot elements. The at least one insertion element is selectively operated to transfer the stator winding into one of the plurality of slots of the arbor member.