Abstract:
An alternator includes a housing, and a stator fixedly mounted relative to the housing. The stator includes a stator winding. The stator winding includes at least five stator leads extending from the stator in an arc that is less than about 90°. A terminal assembly is mounted to an outer surface of the housing and connected with the at least five stator leads. The terminal assembly includes a body formed from a non-electrically conductive material, and a plurality of conductive members at least partially covered by the body. The plurality of conductive members is associated with the stator winding. Each of the plurality of conductive members includes plurality of input connectors spread out along the body in an arc that is greater than 90°.
Abstract:
An internal combustion engine includes a ring gear having a plurality of ring gear teeth. Each of the plurality of ring gear teeth includes a leading edge surface and a trailing edge surface. A starter motor is mounted to the internal combustion engine. The starter motor includes a pinion gear having a plurality of pinion gear teeth configured and disposed to selectively engage with the plurality of ring gear teeth. Each of the plurality of pinion gear teeth includes a leading edge surface portion and a trailing edge surface portion. The pinion gear is configured and disposed to engage with the ring gear while the ring gear is coasting. At least one of the trailing edge surface of each of the plurality of ring gear teeth and the leading edge surface portion of each of the plurality of pinion gear teeth includes a chamfer.
Abstract:
A conductor retention member for a stator core includes a body formed from a non-electrically conductive material. The body includes a radial outwardly facing edge and a radial inwardly facing edge. A plurality of openings extends between the radial inwardly facing edge and the radial outwardly facing edge formed in the body. The body is configured and disposed to be arranged at an axial end of the stator core with the plurality of openings registering with corresponding ones of a plurality of stator slots.
Abstract:
A method of performing active vibration damping in a front end accessory drive (FEAD) system of an automobile using an alternator of the FEAD system and an alternator are described. The method includes determining a resonance to be counteracted, determining a counteracting forcing function to counteract the resonance, and determining a duty cycle change to apply to a field voltage to obtain an output voltage with the counteracting forcing function, wherein the field voltage results in a field current supplied to a rotor that causes a stator to generate the output voltage. The method also includes implementing the duty cycle change for a period of time.
Abstract:
An electric machine includes a stator. The stator includes a stator core, and a plurality of windings supported by the stator core. The plurality of windings include a first end turn portion and a second end turn portion. An adaptable cooling system is fluidically connected to the housing. The adaptable cooling system includes a first coolant circuit configured to guide a coolant in a heat exchange relationship with the stator core, and a second coolant circuit configured to guide a coolant in a heat exchange relationship with one of the first and second end turn portions. A thermal control module is operably connected to the adaptable cooling system. The thermal control module includes a coolant demand schedule described in a machine specific coolant map and is configured and disposed to selectively adapt coolant delivery to the first and second coolant circuits based on the coolant demand schedule.
Abstract:
An electric motor includes a gear assembly having at least one gear arranged within a stationary gear support. The stationary gear support includes an outer surface having an axial retainer mounting element. A drive shaft is operatively coupled to the at least one gear. An output shaft includes a first end and a second end. The second end is operatively coupled to the drive shaft. The output shaft is axially shiftable relative to the drive shaft in a first direction and in an opposing second direction. A clutch assembly is supported on the second end of the output shaft. The clutch assembly includes a clutch shell having a first end and a second end. An axial retainer is detachably mounted to the axial retainer mounting element. The axial retainer is configured and disposed to engage the second end of the clutch shell to limit axial travel of the clutch assembly.
Abstract:
A rotor assembly for a permanent magnet electric machine includes a plurality of rotor laminations joined to form a rotor body. Each of the plurality of rotor laminations includes a plurality of slots. One or more permanent magnets are mounted within respective ones of the plurality of slots. Each of the one or more permanent magnets includes a thermal enhancement bonding coating. A method of forming a rotor assembly is also disclosed.
Abstract:
An electric machine including a housing having a body including an inner surface that defines an interior, a first end defining an opening exposing the interior, and a second end. A stator is fixedly mounted to the inner surface of the housing. A rotor is supported within the interior. The rotor defines an axis of rotation. An end cover extends across the opening adjacent one of the first end and the second end of the stator. A cooling system is carried by the end cover. The cooling system includes a body having a cooling fluid plenum, a plurality of stator nozzles and a plurality of rotor nozzles. The stator nozzles are configured and disposed to direct multiple jets of a coolant toward the stator and the plurality of rotor nozzles are configured and disposed to guide multiple jets of the coolant toward the rotor.
Abstract:
A variable flux electric starter motor includes a frame, an armature rotatably mounted within the frame, and a primary field mounted to the frame. The primary field includes a plurality of primary windings electrically connected one to another. A relay is electrically coupled to at least one of the plurality of poles. A supplemental field is mounted to the frame. The supplemental field includes a supplemental winding electrically connected in parallel to the plurality of primary windings.
Abstract:
An electric machine system includes an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion, a rotor rotatably mounted relative to the stator, and a plurality of switch members are arranged within the switch portion. The plurality of switch members are electrically connected to the stator. A direct current power source is electrically connected to the plurality of switch members. A controller is arranged within a controller housing and electrically connected to the plurality of switch members. The controller housing is distinct from and remotely mounted relative to the AC electric machine. The controller is configured and disposed to activate select ones of the plurality of switch member to convert DC current between the DC power source and an AC current to operate the AC electric machine.