Abstract: An electric motor including a stator, a rotor, and a housing adapted to support the stator and the rotor is provided. The stator includes a stator core, a first and second lamination stack, a flux tube extending therethrough, and windings on the stator core. The rotor includes a hub having an inner surface, a magnet coupled to the hub inner surface, and a shaft received in the stator core for rotation of the rotor relative to the stator about the longitudinal axis of the shaft.

Abstract: A laminated plate assembly in which the laminations in a stack are secured together by means of one or more interlocks or tabs that project from the uppermost lamination in the assembly through holes or slots in all the other laminations in the assembly, or around the periphery of the other laminations in the assembly, with each tab being bent or pressed against the underside of the bottom lamination in the assembly. This secures all the laminations in the stack together, much like a staple secures papers in a stack together, allowing for additional handling and processing of the laminated plate assembly without concern that the laminated plates in the stack will become misaligned or even become removed from the stack.

Abstract: A method and apparatus for progressively cutting, piercing, bending, stacking, and interlocking lamination assemblies from a strip of laminate. The stacked laminations are mechanically interlocked with a staple-style interlock that secures all the laminations in the stack together. All the steps in the process of forming, stacking and interlocking are done within the tool and die assembly, eliminating the need for additional equipment to stack and interlock assemblies.

Abstract: An electric motor including a stator, a rotor, and a housing adapted to support the stator and the rotor is provided. The stator includes a stator core, a first and second lamination stack, a flux tube extending therethrough, and windings on the stator core. The rotor includes a hub having an inner surface, a magnet coupled to the hub inner surface, and a shaft received in the stator core for rotation of the rotor relative to the stator about the longitudinal axis of the shaft.

Abstract: A laminated plate assembly in which the laminations in a stack are secured together by means of one or more interlocks or tabs that project from the uppermost lamination in the assembly through holes or slots in all the other laminations in the assembly, or around the periphery of the other laminations in the assembly, with each tab being bent or pressed against the underside of the bottom lamination in the assembly. This secures all the laminations in the stack together, much like a staple secures papers in a stack together, allowing for additional handling and processing of the laminated plate assembly without concern that the laminated plates in the stack will become misaligned or even become removed from the stack.

Abstract: A method and apparatus for progressively cutting, piercing, bending, stacking, and interlocking lamination assemblies from a strip of laminate. The stacked laminations are mechanically interlocked with a staple-style interlock that secures all the laminations in the stack together. All the steps in the process of forming, stacking and interlocking are done within the tool and die assembly, eliminating the need for additional equipment to stack and interlock assemblies.

Abstract: A motor assembly includes a control sub-assembly configured to be mounted either remotely or integrally to a motor. The control sub-assembly includes a control housing, a control housing cover, electronic control components, and at least one sensing wire connected to the motor. The control housing cover includes a first attachment portion and a second attachment portion. The first attachment portion attaches the control housing cover to the control housing and the second attachment portion attaches the control housing cover to the motor. If the control sub-assembly is to be mounted remotely from the motor, the second attachment portion is not connected to the motor.

Abstract: A rotor position sensor mounting system includes a sensor assembly fixedly engaged with a stator assembly. The stator assembly includes a plurality of stator laminations including a plurality of sections separated by a plurality of first gaps. Each first gap is defined by a first pair of edges. The stator assembly also includes first and second stator end caps attached to the stator laminations and including a plurality of sections separated by a plurality of second gaps. Each second gap is defined by a pair of stator end cap section edges. At least one pair of stator end cap section edges includes a first notch and a second notch separated by a bridge. The sensor assembly engages the second notch and is maintained in position with the bridge and the stator laminations.

Abstract: A motor assembly includes a control sub-assembly configured to be mounted either remotely or integrally to a motor. The control sub-assembly includes a control housing, a control housing cover, electronic control components, and at least one sensing wire connected to the motor. The control housing cover includes a first attachment portion and a second attachment portion. The first attachment portion attaches the control housing cover to the control housing and the second attachment portion attaches the control housing cover to the motor. If the control sub-assembly is to be mounted remotely from the motor, the second attachment portion is not connected to the motor.

Abstract: An electric motor includes a rotor cup housing having an annular flange extending circumferentially from a sidewall. The motor further includes a stator including a stator core having a winding thereon and a rotor positioned at least partially around the stator. A rotor shaft is positioned at least partially within the stator.

Abstract: A connector plug gap sealer that fits smoothly within an internal cavity of a connector plug includes a first section, a second section, and a third section, the second section includes a flat section and a guiding section, the third section extending from the guiding section around the horizontal axis of symmetry. The first, second and the third sections configured into a single unitary piece to define the plug gap sealer having a flat bottom surface around the horizontal axis of symmetry of the plug gap sealer. The method associated with installing the connector plug gap sealer is also disclosed.

Abstract: A rotor position sensor mounting assembly includes a housing, a hall effect device, a printed circuit board, a plurality of leads, and a cable tie. The housing includes two pairs of guides that fixedly attach the housing to a stator end cap and a plurality of stator laminations. The second pair of housing guides extend substantially flush with the top wall. A gap extends between the first pair of housing guides and the second pair of housing guides and the first pair of housing guides has a wedge shape. In addition, a pair of internal guides extend from the second side walls into the cavity such that the internal guides form the cavity into a substantially inverted T at a first end of the housing to precisely locate the hall effect device.

Abstract: A method for assembling an inside out motor includes the step of stacking a plurality of laminations together to form a pole member. A stator is molded around the pole member so that an end of the pole member is located adjacent an exterior surface of the molded stator. An electrically conductive magnet wire is wound around the molded stator adjacent the pole member to form a winding of the motor.

Abstract: An inside out motor includes a rotor including a concave member, a shaft defining a longitudinal axis mounted on the concave member and a magnet mounted on an interior surface of the concave member. A bearing receives the shaft for rotatably mounting the rotor. A stator assembly is mounted on said bearing and includes a bobbin mounted generally coaxially with the rotor shaft and having an interior diameter, an exterior diameter, a first axial end and a second axial end. A winding is wound on the bobbin and extends around the axis of the rotor shaft. The winding has a width in a direction parallel to the lengthwise extension of the rotor shaft. Plural separate ferromagnetic members are on each of the first and second axial ends of the bobbin. Each ferromagnetic member has a radially outer leg extending generally between the winding and the magnet.

Abstract: An electric motor having a snap-together construction without the use of separate fasteners. The construction of the motor removes additive tolerances for a more accurate assembly. The motor is capable of programming and testing after final assembly and can be non-destructively disassembled for repair or modification. The motor is constructed to inhibit the ready entry of water into the motor housing and to limit the effect of any water which manages to enter the housing.

Abstract: An electric motor having a snap-together construction without the use of separate fasteners. The construction of the motor removes additive tolerances for a more accurate assembly. The motor is capable of programming and testing after final assembly and can be non-destructively disassembled for repair or modification. The motor is constructed to inhibit the ready entry of water into the motor housing and to limit the effect of any water which manages to enter the housing.

Abstract: A motor having an external rotor, or "inside out motor" has a split C arrangement of ferromagnetic members which function as the poles of the electromagnet in the motor. The ferromagnetic members are generally C-shaped and mounted on opposite end caps of the motor. The ferromagnetic members on the opposing end caps are angularly offset from each other. The ferromagnetic members on each end cap are also spaced apart from each other, and receive a portion of the motor windings within them. The motor is constructed for assembly using few or no separate fastening devices to secure the components together. In one embodiment, a bearing core serves as the base on which all parts are assembled.

Abstract: An inside out electric motor includes a rotor having an interior surface defining an interior space and a magnetic element mounted on the rotor. The motor also includes a stator having a bobbin. The bobbin has a bearing positioned at a central axis of the bobbin. The bearing rotatably engages the rotor to permit the rotor to freely rotate with respect to the stator. The bobbin also has a pole member molded into the bobbin so that an end of the pole member is spaced radially inward from and at least partially aligned with the magnetic element, and a winding wound around the bobbin so that the winding passes adjacent the pole member.

Abstract: A rotor end cap for use with a rotor of a dynamoelectric machine to induce cooling air circulation, facilitate rotor balancing and enable rotor rotational position and speed sensing. The rotor end cap includes a base for attachment to a rotor of the dynamoelectric machine so that the base turns with the rotor. Further, the end cap includes a plurality of blades extending from the base in axial and radial directions with respect to the rotor for moving air to enhance cooling air circulation within the machine as the rotor turns. Still further, the end cap includes a balancing device extending from the base for altering a weight distribution around the base to balance the rotor. Yet still further, the end cap includes at least one shutter extending partially around the base for intermittently blocking passage of light as the rotor turns to enable rotational position and speed sensing of the rotor.