Abstract: A method for determining optimum enamel die sizes for each of a plurality of dies for fabricating magnet wire includes a series of calculations based upon an empirically determined build factor for each of the enamel coatings used in the fabrication process. The build factor is a measure of the effective diameter increase of a wire passed through a coating die when the diameter of the wire entering the die is known and a selected thickness of wet enamel coating exiting the die is known. The build factor a given enamel coating is primarily dependent upon only the solids content of the enamel coating solution, and is largely independent of the chemistry of the coating solution. A simple relationship between build factor, die size, and wire size allows consistent fabrication of magnet wire in accordance with pre-selected specifications and with virtually no scrapped wire due to oversized final wire diameters.

Abstract: Methods and apparatus for minimizing electrical machine vibration are described. In an exemplary embodiment of the method, power is applied to the motor under microprocessor control such that a pulse modulated current profile is applied to the motor which in turn controls the amount of torque generated by the motor. By adjusting current profiles, torque generation is controlled, and vibration and noise are eliminated.

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 energy efficient low-power integral electronically commutated fan motor and control circuit assembly mounted on a circuit board for use in refrigerators utilizing a Hall sensor to provide positional control signals for sequential energization of the windings with the Hall sensor energization being pulsed, and the motor stator windings energized only during a portion of the period, when rotational torque produced by the energization is greatest in order to reduce the power input to the assembly. Integrally molded multi-function components including the coil bobbin, ground pin, Hall sensor holder, motor bearing oil well covers, and assembly housing provide positioning, support, and securing assistance along with electrical and magnetic operative connections and positioning.

Abstract: A sump pump motor switch assembly for a sump pump including a motor casing and an end shield, includes a switch assembly and a housing mounted to the end shield. A cam actuator is connected to the housing and a sump pump actuation switch is mounted with the cam actuator. A motor actuation switch is also mounted with the cam actuator body. The sump actuation switch and the motor actuation switch are snap action switches that are simultaneously actuated by the cam actuator. The switch assembly includes a snap fitting assembly configured to fit into a receiving retainer within the motor casing.

Abstract: A mimic filter which can be implemented in analog or digital circuitry, and which removes dc offset or other noise from an input signal using a pseudo-differentiation technique. The input signal is adjusted by a feedback value, and the adjusted signal is amplified by a proportional gain factor to generate an output signal. The feedback value is determined by integrating the output signal and multiplying the integration by an integration gain factor. The mimic filter avoids the generation of false signal spikes.

Abstract: A mounting assembly for an electric motor with deep drawn endshields includes a resilient outer ring and a split inner ring for gripping engagement with an outer surface of a bearing endshield. The gripping engagement is sufficient to hold the mounting assembly to the motor but insufficient to deform the endshields. The inner ring is distanced slightly from first and second ends of the mounting assembly to isolate and damp motor vibration and prevent vibration transmission to a mounting base.

Abstract: The present invention, in one embodiment, is a method for controlling data flow in an electronic electric meter. The method includes steps of measuring current and voltage of a power source; determining a set of internal quantities using the measured current and voltage; using the set of internal quantities in conjunction with a set of functions to determine measurement profile quantities; and storing the determined measurement profile quantities in registers within the meter.

Abstract: A gating system for vertical die casting of a squirrel cage rotor includes an upper end ring cavity, a lower end ring cavity, and a plurality of passages in fluid communication with the upper and lower end ring cavities for forming rotor bars. A gate is radially distanced from the passages, and molten metal is injected into the lower end ring cavity and fills the lower end cavity before filling the passages. The passages are therefore filled at approximately the same time and rate until the passages are full and the upper end ring cavity fills with molten metal.

Abstract: A method for controlling an electronically commutated motor (ECM) using an air moving system including a controller and an interface board, the interface board electrically coupled to the controller. The ECM electrically coupled to the interface board. The ECM includes a motor controller having an ECM program and the interface board includes a mode signal circuit and a tap signal circuit. The method includes transmitting control signals to the interface board, translating the signals into signals suitable for controlling the ECM, and operating the ECM based on the translated signals.

Abstract: A system for motor thermal protector device performance test data collection includes a microprocessor configured to measure elapsed times of reset and trip power cycles of a motor winding through a thermal protector device. An operator interface terminal is coupled to the microprocessor and includes a display and input selectors for recalling a predetermined number of elapsed reset and trip times stored in a system memory.

Abstract: A stator yoke formed with a plurality of layers of similarly sized metal sheets is disclosed. A plurality of gaps extend through the stator yoke between ends of the metal sheets. The gaps decrease in size from an outer layer to an inner layer of the stator yoke. The stator yoke can be formed to have a limited tolerance even when the metal sheets do not have limited tolerances.

Abstract: A motor drive system includes an electric motor including a rotor shaft, a first main winding and a second main winding. The first and second main windings are selectively energizable to operate the motor at first and second speeds, and at least one of the windings is a permanent split capacitor winding. A transmission is coupled to the rotor shaft, and the rotor shaft engages the transmission without employing a clutch mechanism.

Abstract: A fan assembly includes a shroud attached to a motor housing to prevent negative pressure from developing within the motor housing and prevent moisture from being drawn into drain openings. The assembly includes a fan, a motor, a motor housing, and a fan control. The motor and fan control are disposed within the motor housing. The motor housing includes drain openings to permit the motor housing to be assembled and to permit moisture to drain to the environment from the motor housing. The shroud is attached downstream from the fan such that the drain openings remain open to the environment.

Abstract: A circuit is provided for use in a synchronous generator excitation system. The circuit comprises a three-phase bridge having six legs. The bridge is connected with an AC power supply. A thyristor is provided in each of the six legs, wherein the thyristors provide a path for a device current. A free wheeling diode functions as a de-excitation means connected in parallel with the three-phase bridge. The free wheeling diode provides a discharge path for a field current.

Abstract: A fan assembly includes a vibration damping system to reduce induced vibrational energy generated as a result of fan motor operation. The vibration damping system includes a plurality of arms and damping material. The vibration damping system arms extend between a fan motor housing and a shroud assembly disposed circumferentially outward from the fan motor housing. The damping material is attached to an end of each of the vibration damping system arms and connects each arm to the shroud assembly. The damping material absorbs induced vibrational energy generated by fan motor operation.

Abstract: Systems, methods and apparatus for winding conductive wires for a stator of an electric motor. In one embodiment, a hysteretic tensioning apparatus is utilizing to substantially stabilize tension in a conductive wire supplied to a winding machine. The hysteretic tensioning apparatus includes a support member, a brake member, and four idler arms. The brake member is rotatably mounted to the brake member and configured to engage the conductive wire. The idler arms each are spring mounted to the support member and also are configured to engage the conductive wire. The conductive wire is extended across the support member so that it extends between adjacent idler arms and the brake and is inserted into the winding machine.

Abstract: Methods and control systems for improving performance in an air filtration system are disclosed. The method includes monitoring performance of a blower motor in the air filtration system and adjusting blower motor torque based upon a measured airflow or a measured static air pressure within the air filtration system.

Abstract: A power supply booster module for a programmable logic controller system replaces the primary power supply for a number of modules within the system. The power supply booster module allows high power consuming or highly complex modules to be used within a programmable logic controller system. The power supply booster module eliminates the problems present in prior programmable logic controller systems where the primary power supply could not output enough current to adequately power all of the system modules or modules that have a high power requirement.

Abstract: Grouped gating control logic allows for one or more inputs in a group to be active at any given time. Once an input signal in a group is active, all other pulse trains received in the same group can be locked out. Thus, by using a finite state machine to control gate pulses, the noise margin of the gating unit can be regulated and an extra level of protection is available should one of the input gating signals be defective.