Abstract: An electric motor comprises a shaft, an interior magnet rotor core comprising a central bore and a pair of opposing ends faces, and at least one resilient structure inserted within the central bore between the pair of opposing end faces. The at least one resilient component is inserted within the central bore between the pair of opposing end faces such that the at least one resilient component does not extend beyond one of the opposing end faces. The resilient component comprises an outer rigid structure inserted within the central bore, a resilient component inserted within the outer rigid structure, and an inner rigid structure inserted within the resilient component, wherein the shaft is inserted through the inner rigid structure.

Abstract: A method for manufacturing an interior magnet rotor core motor is described herein. The method includes attaching a resilient material to an inner rigid structure configured to engage a shaft associated with the motor, engaging the structure with the motor shaft, positioning the shaft and structure assembly with respect to the rotor core, and affixing the resilient material to the rotor core.

Abstract: A permanent magnet rotor includes at least one permanent magnet and a rotor core including a first end and a second end. The rotor core includes a plurality of permanent magnet openings that are each configured to receive a permanent magnet. The permanent magnet rotor also includes a first rotor end lamination coupled to the first rotor core end. The first rotor end lamination includes a plurality of inner lamination walls defining a first lamination opening and a second lamination opening circumferentially adjacent the first lamination opening. At least one inner lamination wall includes at least one permanent magnet retention feature configured to secure the permanent magnet within a corresponding permanent magnet opening. The at least one permanent magnet retention feature includes at least one tab extending radially from at least one of the plurality of inner lamination walls within the first rotor end lamination.

Abstract: A permanent magnet rotor includes at least one permanent magnet and a rotor core including a first end and a second end. The rotor core includes a plurality of permanent magnet openings that are each configured to receive a permanent magnet. The permanent magnet rotor also includes a first rotor end lamination coupled to the first rotor core end. The first rotor end lamination includes a plurality of inner lamination walls defining a first lamination opening and a second lamination opening circumferentially adjacent the first lamination opening. At least one inner lamination wall includes at least one permanent magnet retention feature configured to secure the permanent magnet within a corresponding permanent magnet opening. The at least one permanent magnet retention feature includes at least one tab extending radially from at least one of the plurality of inner lamination walls within the first rotor end lamination.

Abstract: A method for securing a permanent magnet within a rotor core is described. The rotor core includes a first end and a second end and at least one permanent magnet opening configured to receive the permanent magnet. The method includes coupling a first rotor end lamination to the first end of the rotor core. The first lamination includes at least one inner wall that defines an opening within the first lamination that corresponds to the permanent magnet opening in the rotor core. The first lamination includes a bridge portion positioned between the at least one inner wall and an outer edge of the first rotor end lamination. The method also includes positioning a permanent magnet at least partially within the permanent magnet opening and mechanically deforming the bridge portion of the first lamination to secure the permanent magnet within the permanent magnet opening.

Abstract: An electric motor comprises a shaft, an interior magnet rotor core comprising a central bore and a pair of opposing ends faces, and at least one resilient structure inserted within the central bore between the pair of opposing end faces. The at least one resilient component is inserted within the central bore between the pair of opposing end faces such that the at least one resilient component does not extend beyond one of the opposing end faces. The resilient component comprises an outer rigid structure inserted within the central bore, a resilient component inserted within the outer rigid structure, and an inner rigid structure inserted within the resilient component, wherein the shaft is inserted through the inner rigid structure.

Abstract: A method for securing a permanent magnet within a rotor core is described. The rotor core includes a first end and a second end and at least one permanent magnet opening configured to receive the permanent magnet. The method includes coupling a first rotor end lamination to the first end of the rotor core. The first lamination includes at least one inner wall that defines an opening within the first lamination that corresponds to the permanent magnet opening in the rotor core. The first lamination includes a bridge portion positioned between the at least one inner wall and an outer edge of the first rotor end lamination. The method also includes positioning a permanent magnet at least partially within the permanent magnet opening and mechanically deforming the bridge portion of the first lamination to secure the permanent magnet within the permanent magnet opening.

Abstract: A method for manufacturing an interior magnet rotor core motor is described herein. The method includes attaching a resilient material to an inner rigid structure configured to engage a shaft associated with the motor, engaging the structure with the motor shaft, positioning the shaft and structure assembly with respect to the rotor core, and affixing the resilient material to the rotor core.

Abstract: A rotor assembly for an electric motor is described that includes a rotor shaft, a ferromagnetic core mounted on the rotor shaft, and at least one cylindrical shaped magnet configured to engage and substantially surround the length of the ferromagnetic core. The at least one magnet is fabricated utilizing neodymium.

Abstract: A motor is described that includes a motor enclosure, a motor winding assembly, a motor control unit, and a mid shield. The motor enclosure includes a plurality of protrusions into the motor enclosure in a substantially configuration around its perimeter and the motor winding assembly is configured for placement within the motor enclosure. A portion of the motor control unit is configured for placement within the motor enclosure and the mid shield is configured for placement within the motor enclosure between the motor control unit and the motor winding assembly where it engages the protrusions upon insertion into the enclosure.

Abstract: A magnet motor with rotor assembly is provided that has a plurality of magnet members that circumscribe a wall of the rotor core or stator in an orientation that minimizes or eliminates gaps therebetween. The magnet members can have non-parallel opposing sides to allow for elimination of the gaps. The magnet members may have trapezoidal-like shapes.

Abstract: A rotor assembly comprising: a rotor having an outer circumference and a longitudinal axis; and a plurality of magnet members secured to said outer circumference, each of said plurality of magnet members having a degree of curvature about said longitudinal axis, wherein a sum of said degrees of curvature is greater than 355.5 degrees.

Abstract: A method for varying motor output using magnets of different fluxes includes manufacturing standardized parts, ascertaining desired motor output, selecting from a group of interchangeable magnets to provide the desired output, and assembling a motor with the selected magnets and standardized parts such that the desired output is provided. Additionally, a motor kit including a rotor configured to accommodate magnets of varying residual induction values and lengths, a stator configured to operate with the rotor, and a plurality of interchangeable magnets with different residual induction values and lengths.

Abstract: A method for varying motor output using magnets of different fluxes includes manufacturing standardized parts, ascertaining desired motor output, selecting from a group of interchangeable magnets to provide the desired output, and assembling a motor with the selected magnets and standardized parts such that the desired output is provided. Additionally, a motor kit including a rotor configured to accommodate magnets of varying residual induction values and lengths, a stator configured to operate with the rotor, and a plurality of interchangeable magnets with different residual induction values and lengths.

Abstract: A rotor mount assembly, located between a rotor shaft and a plurality of magnetic elements, resiliently damps vibrations induced from the plurality of magnetic elements. The rotor mount assembly includes a first resilient ring, a second resilient ring, and a laminated spacer. The laminated spacer includes laminates from a stator core center punch. Both resilient rings include an inner metal insert which, in one embodiment, comprises laminates.

Abstract: A rotor mount assembly, located between a rotor shaft and a plurality of magnetic elements, resiliently damps vibrations induced from the plurality of magnetic elements. The rotor mount assembly includes a first resilient ring, a second resilient ring, and a laminated spacer. The laminated spacer includes laminates from a stator core center punch. Both resilient rings include an inner metal insert which, in one embodiment, comprises laminates.

Abstract: A method for facilitating the reduction of transmitted motor noise using a mounting system in a frame. The mounting system includes a motor assembly having an end bell, a mounting bracket including a brace, a plurality of attachment openings, a plurality of leaf springs attached to the brace and an anchor device attached to each leaf spring. Each anchor device includes a fastener opening and a grommet. The leaf springs and grommets are configured to filter and damp noise transmitted from the motor to the frame.

Abstract: Method of operating an electronically commutated motor, controlled by a board mounted electronic circuit, wherein current surges in such circuit are suppressed while dissipating heat associated with such suppression from motor structure as opposed to the control circuit. The heat associated with control circuit current surge suppression is dissipated into the bowels of the motor as opposed to being dissipated from a heat generating resistor mounted on the control circuit board as has been done heretofore. Illustrated structure includes current surge suppressing special winding turns on the motor core. Such special winding turns are connected with a known electronic control circuit so that power supplied to such circuit is transmitted through the special winding on the motor. Current surges associated with operation of the motor control circuit are then suppressed, during operation, by the special winding inside the motor.