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公开(公告)号：US20210288564A1
公开(公告)日：2021-09-16
申请号：US17160493
申请日：2021-01-28
Applicant: BorgWarner Inc.
Inventor： Joshua B. Lahrman , David A. Fulton
Abstract: A rotor includes a shaft having an outer surface including a first diameter and a flange extending from the outer surface. A first plurality of laminations is arranged about the shaft. The first plurality of laminations includes an outer annular surface and an inner surface defining an opening including a second diameter that is substantially equal to the first diameter. A second plurality of laminations is arranged about the shaft and coupled to the first plurality of laminations. The second plurality of laminations include an outer annular surface portion and an inner surface portion defining a third diameter that is greater than the first diameter.
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公开(公告)号：US12231000B2
公开(公告)日：2025-02-18
申请号：US17716144
申请日：2022-04-08
Applicant: BorgWarner Inc.
Inventor： Kirk Neet , Joshua B. Lahrman , Matthew R. Conner , David A. Fulton
Abstract: A stator for an electric machine includes a core and a multi-phase winding arrangement positioned on the core. Each phase of the winding arrangement includes a plurality of parallel paths defining a plurality of poles for the electric machine. Each parallel path includes a plurality of coils positioned on the core, each coil defined by coil legs and end turns. The coil legs include left legs and right legs extending through the slots of the core. The left legs and right legs of each coil are connected by first end turns at one end of the core and second end turns at an opposite end of the core. Each pole of the electric machine is associated with a pole slot set comprised of multiple slots on the stator core. For each pole slot set, legs for each parallel path extend through one of the slots of said pole slot set.
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公开(公告)号：US20230216362A1
公开(公告)日：2023-07-06
申请号：US17569925
申请日：2022-01-06
Applicant: BorgWarner Inc.
Inventor： Matthew R. Conner , Joshua B. Lahrman
CPC classification number: H02K3/12 , H02K3/28 , H02K1/16 , H02K15/045
Abstract: A method of forming a diamond coil wound stator winding including introducing a plurality of diamond coils into a plurality of slots of a linear magazine forming a diamond coil wound stator winding, transferring the diamond coil wound stator winding into a circular cassette, and shifting the diamond coil wound stator winding from the circular cassette into a plurality of slots arranged in an inner annular surface of a stator core in a single operation.
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公开(公告)号：US12149136B2
公开(公告)日：2024-11-19
申请号：US17716092
申请日：2022-04-08
Applicant: BorgWarner Inc.
Inventor： Gabriel Domingues , Joshua B. Lahrman , Matthew R. Conner , Kirk Neet , David A. Fulton
Abstract: A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).
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公开(公告)号：US11916441B2
公开(公告)日：2024-02-27
申请号：US17160493
申请日：2021-01-28
Applicant: BorgWarner Inc.
Inventor： Joshua B. Lahrman , David A. Fulton
Abstract: A rotor includes a shaft having an outer surface including a first diameter and a flange extending from the outer surface. A first plurality of laminations is arranged about the shaft. The first plurality of laminations includes an outer annular surface and an inner surface defining an opening including a second diameter that is substantially equal to the first diameter. A second plurality of laminations is arranged about the shaft and coupled to the first plurality of laminations. The second plurality of laminations include an outer annular surface portion and an inner surface portion defining a third diameter that is greater than the first diameter.
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Patent Agency Ranking
公开(公告)号：US10851754B2
公开(公告)日：2020-12-01
申请号：US15646809
申请日：2017-07-11
Applicant: BorgWarner Inc.
Inventor： Joshua B. Lahrman
Abstract: A solenoid for a motor vehicle starter includes at least one coil wound on at least one spool, the at least one coil defines a toroidal space encircling the at least one coil. A stop member is positioned adjacent to the at least one spool. A diode holder is positioned in the toroidal space defined by the at least one coil, and a diode is positioned in the diode holder. The diode includes a cylindrical body, a first lead extending from a first end of the cylindrical body, and a second lead extending from a second end of the cylindrical body. The cylindrical body of the diode is retained by the diode holder within the toroidal space, and the first lead of the diode extends out of the toroidal space and is electrically connected to the stop member.
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公开(公告)号：US12119721B2
公开(公告)日：2024-10-15
申请号：US17552883
申请日：2021-12-16
Applicant: BorgWarner Inc.
Inventor： Matthew R. Conner , Joshua B. Lahrman
CPC classification number: H02K3/50 , H02K15/0062 , H02K2203/06
Abstract: A stator for an electric machine comprises a cylindrical stator core, windings positioned on the stator core, and an end disc positioned an end of the stator core. The stator core defines an inner diameter and an outer diameter. A plurality of slots are formed in the core and extend radially from the inner diameter toward the outer diameter. The windings include in-slot portions, end turns, and at least one jumper. The end disc defines a plurality of slots aligned with the slots of the stator core and at least one dog hole removed from the slots of the end disc. The at least one jumper is bent circumferentially around the dog hole and connects two of the in-slot portions of the windings.
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公开(公告)号：US20230198329A1
公开(公告)日：2023-06-22
申请号：US17552883
申请日：2021-12-16
Applicant: BorgWarner Inc.
Inventor： Matthew R. Conner , Joshua B. Lahrman
CPC classification number: H02K3/50 , H02K15/0062 , H02K2203/06
Abstract: A stator for an electric machine comprises a cylindrical stator core, windings positioned on the stator core, and an end disc positioned an end of the stator core. The stator core defines an inner diameter and an outer diameter. A plurality of slots are formed in the core and extend radially from the inner diameter toward the outer diameter. The windings include in-slot portions, end turns, and at least one jumper. The end disc defines a plurality of slots aligned with the slots of the stator core and at least one dog hole removed from the slots of the end disc. The at least one jumper is bent circumferentially around the dog hole and connects two of the in-slot portions of the windings.
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公开(公告)号：US20220329124A1
公开(公告)日：2022-10-13
申请号：US17716092
申请日：2022-04-08
Applicant: BorgWarner Inc.
Inventor： Gabriel Domingues , Joshua B. Lahrman , Matthew R. Conner , Kirk Neet , David A. Fulton
Abstract: A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).
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公开(公告)号：US20220329116A1
公开(公告)日：2022-10-13
申请号：US17716144
申请日：2022-04-08
Applicant: BorgWarner Inc.
Inventor： Kirk Neet , Joshua B. Lahrman , Matthew R. Conner , David A. Fulton
Abstract: A stator for an electric machine includes a core and a multi-phase winding arrangement positioned on the core. Each phase of the winding arrangement includes a plurality of parallel paths defining a plurality of poles for the electric machine. Each parallel path includes a plurality of coils positioned on the core, each coil defined by coil legs and end turns. The coil legs include left legs and right legs extending through the slots of the core. The left legs and right legs of each coil are connected by first end turns at one end of the core and second end turns at an opposite end of the core. Each pole of the electric machine is associated with a pole slot set comprised of multiple slots on the stator core. For each pole slot set, legs for each parallel path extend through one of the slots of said pole slot set.
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