Abstract: A technique is provided for sealing a bearing cavity in a rotating machine such as an electric motor. The bearing cavity is defined by annular elements on either side of an antifriction bearing set. Seals are provided on the sides of the bearing cavity and are secured to a support structure, such as the motor housing, and include elements which ride against the rotating shaft during operation. The seals exert a sealing force against the rotating element which results at least partially from internal pressure within the bearing cavity provided by a pressurized lubricant stream. The lubricant stream is provided in the form of an airborne oil mist.

Abstract: A corrosion resistant bearing includes a bearing insert and a housing supporting the bearing insert. The bearing insert includes an outer ring, an inner ring and a plurality of rolling bearing elements disposed between the rings. At least one of the bearing components includes a multi-layer corrosion resistant system for inhibiting or delaying corrosion of the substrate of the component. The substrate may be made of high carbon or alloy steel. The corrosion resistant system includes a galvanic or sacrificial metallic plating layer disposed directly on the component substrate. One or more mechanical protection layers is formed or disposed over the plating layer. A first mechanical protection layer includes a clear chromate coating formed on the plating layer. Additional mechanical protection layers include non-metallic layers, such as acetate or polytetrafluoroethylene coatings.

Abstract: An instrumented dead shaft is provided for a rotating machine system, such as a drum pulley. The shaft includes bearing support regions for receiving bearings for supporting a rotating element. The shaft also includes at least one sensor assembly, and preferably a number of sensor assemblies for sensing operating parameter of the shaft system. In a preferred configuration, the system includes a rotational speed sensor, temperature sensors, load sensors, and an accelerometer. The speed sensor detects rotational speed of the rotating element and applies an output signal representative thereof to an interface circuit. The temperature sensors provide an indication of the bearing temperatures. The load sensors provide an indication of the strain of the shaft during loading. Output signals from all sensors are transmitted to a control and monitoring circuit via network interfaces. The data links between network interface circuitrys and the sensors are embedded in the shaft.

Abstract: An adapter assembly for rotationally joining a first rotational member to a second rotational member is provided including a first adapter, a first bearing within the first adapter, a second adapter, a second bearing within the second adapter, and a connecting assembly. A power transmission assembly is provided, suitable for use with any one of a family of motors of different sizes, the assembly including a motor selected from the family, a speed reducer, a first adapter, a first bearing, a second adapter, a second bearing, and a connecting assembly. The first adapter is sized for use with at least two of the motors, and the first bearing is chosen from a family of bearings of different sizes, each sized for use with a corresponding one of the motors within the family. The first bearing is sized for use with the motor.

Abstract: A technique for forming stator coils for an electric motor is disclosed. The technique includes forming D-shaped or generally trapezoidal coils having a closed loop defining a long side and a short side joined by end portions. The coils are installed in a stator core having a plurality of slots formed around its inner periphery. The long sides of the coils are disposed in a predetermined position within these slots, such as in a lower position, while the short sides are disposed in opposite positions, such as in upper positions. The long sides extend beyond the short sides at end regions of the stator core. The end portions of each coil wrap around the ends of the stator core and incline from the long side of the respective coil to the short side thereof. Crossing points are established between the long side of each coil and end portions of adjacent coils.

Abstract: A system for detecting defects in a rotating machine system includes a sensor such as an accelerometer coupled to the machine system for detecting vibrations of a rotating element. Output of the accelerometer is transmitted, preferably via a network data link to a monitoring/control circuit. The monitoring/control circuit analyzes the vibration data to develop a normal vibration profile for the machine system during a normal operating phase. The normal vibration profile is stored in a memory circuit for later reference. During subsequent operation of the machine system, the monitoring/control circuit cyclically analyzes vibration data to develop actual vibration profiles. The actual vibration profiles are compared to the normal vibration profile and, where variations between the profiles exceed preset tolerances, the circuit provides an indication of a malfunction or defect in the machine system.

Abstract: A system provides feedback to an operator of a steer-by-wire system. In steer-by-wire systems, there is no direct mechanical connection between the vehicle steering wheel and the steering gears. The present invention utilizes a sensor to sense torque values at the steering gears. The sensor communicates signals back to the steering wheel as operator feedback. The sensed and communicated torque values include high frequency torque fluctuations to provide road-feel in steer-by-wire systems. Also, the torque can be used to make predictions of the operator's conditions and the condition of the steering system.

Abstract: A network, network connector and method are provided for transmitting power and data signals between device nodes. The network utilizes a trunk cable in which a pair of power conductors and a pair of signal conductors are embedded in an insulative cover. The connector makes contact with the power and signal conductors during installation, such as by contact members which pierce the insulative cover of the cable. The connector has a base portion and an interface portion fitted to the base portion. A capacitor is disposed in the base portion and electrically coupled across the power conductors when the connector is installed. A node device is coupled to the cable via the interface module. When the device draws power from the cable, the capacitor limits perturbations of the supply voltage to reduce differential mode noise on the signal conductors.

Abstract: A molded polymeric bearing housing is formed of a moldable polymer base material in combination with a glass fiber reinforcing component. A foaming agent is added to the base material to create a fine structural foam within interior regions of the housing. A density gradient is established between regions adjacent to the surfaces of the housing and the internal regions, thereby reducing the need for reinforcing ribs particularly in a base or mounting portion of the housing. An antimicrobial agent may be added to the housing material to inhibit the growth and proliferation of fungi, molds, bacteria, and so forth. Structural features of the housing may be formed subsequent to the molding process, such as by turning operations. Metal inserts may be provided to avoid crushing of regions of the housing, such as by attachment fasteners. The housing forms a mounting base surface in a single plane coextensive with the footprint of the housing.

Abstract: A corrosion resistant bearing includes a bearing insert and a housing supporting the bearing insert. The bearing insert includes an outer ring, an inner ring and a plurality of rolling bearing elements disposed between the rings. At least one of the bearing components includes a multi-layer corrosion resistant system for inhibiting or delaying corrosion of the substrate of the component. The substrate may be made of high carbon or alloy steel. The corrosion resistant system includes a galvanic or sacrificial metallic plating layer disposed directly on the component substrate. One or more mechanical protection layers is formed or disposed over the plating layer. A first mechanical protection layer includes a clear chromate coating formed on the plating layer. Additional mechanical protection layers include non-metallic layers, such as acetate or polytetrafluoroethylene coatings.

Abstract: A multiphase circuit interrupter includes a plurality of power phase sections for establishing and interrupting electrical power carrying paths for a plurality of phases. Each power phase section includes first and second conductive regions which contact one another to complete the current carrying path for the phase. The second conductive region is movable to an interrupted position to interrupt the path. An interphase current carrying path is established between the power phase sections to conduct electrical energy between the sections following a trip event in any one of the sections. The interphase current carrying path may be established by a conductive element extending between the power phase sections. Channels may be formed in the interrupter housing between the power phase sections to communicate conductive plasma generated during separation of the contact regions from one another between the power phase sections.

Abstract: A method for retaining a movable contact in a circuit interrupter is applicable to interrupters including first and second contacts, at least one of the contacts being movable. A movable element supporting the movable contact is displaceable between a conducting position wherein the movable contact abuts a cooperating contact to complete a current carrying path through the device, and a non-conducting position wherein the movable contact is electrically separated from the cooperating contact. In accordance with the method, the movable contact is displaced by an interrupt initiation device, and a carrier or retainer is displaced by gas pressure resulting from arcs generated by movement of the contact. The carrier is guided in its displacement within the device housing from a normal operating position to a retaining position. The carrier includes an abutment element that physically contacts the movable element to prevent it from rebounding into contact with the cooperating contact.

Abstract: An inductive proximity sensor and a method of proximity sensing are described that permit targets of interest to be detected despite the presence of external magnetic fields due to AC or DC sources, such as resistive welding machines. The sensor has a pair of matched coils positioned adjacent to one another along a common central axis. The coils are coupled in series with oscillator and detecting circuitry, that also serves to drive a switching device. The coils are wound for current flow in opposite directions and produce oscillating electro-magnetic fields for detecting the targets in response to signals from the oscillator and detecting circuitry. Currents in the coils induced by strong external magnetic fields produces an additional components of the coil field which essentially cancel one another. The sensing field of the coil assembly may be shaped and directed by cooperation of the fields of the two coils and by appropriate shielding around one or both coils.

Abstract: A coupling/mounting system for securing a shaft to a sleeve or hub includes an inner insert or bushing and an outer insert or bushing. The inner bushing has a slot permitting its radial compression during insertion into the hub. One or more radially extending projections are provided about the cylindrical outer periphery of the inner bushing. The projections enter into engagement in a corresponding recess within the bore. The inner bushing has a tapered inner surface that contacts a corresponding tapered outer surface of the outer bushing. The outer bushing has a elongated slot that permits its radial compression about the shaft when the system is assembled. The outer bushing includes mechanical features which permit it to be drawn into engagement between the inner bushing and the shaft, and thereby to exert radial forces for securing the shaft to the bore.

Abstract: A biasing assembly for a switching device is formed in a modular enclosure that may be mounted on either left or right sides of the switching device. The biasing assembly interfaces with the switching device to rapidly move the switching device between first and second stable positions, such as corresponding to open and closed contact orientations. The biasing assembly includes a hub and link plate coupled to a spring assembly. A spring in the spring assembly is precharged by initial movement of an actuating handle. Once a predetermined intermediate position is reached, a double roller arrangement is displaced along a support surface to rapidly toggle the spring assembly, link plate and hub to a second position. The enclosure includes abutment surfaces for stopping and holding the link plate in stable positions. The rolling contact afforded by the spring assembly rollers permits extremely rapid displacement and rolling friction during displacement of the assembly.

Abstract: A brushless DC motor and drive package is disclosed, including modular subassemblies which are integrated into a single unit. The drive includes power electronic circuitry and related control circuitry which is supported on a circuit board within the package. The circuit board is supported on an end cap of the motor and is housed within the package housing. The end cap supporting the circuit board preferably forms a bearing support recess for receiving a shaft bearing. The resulting package is extremely compact, and reduces or eliminates the need for separate drive circuitry and related support hardware.

Abstract: An integral brushless DC motor and drive package is disclosed that includes the brushless DC motor and drive circuitry supported by one of the motor end caps. The drive circuitry includes power electronic devices for converting input power to pulsed power for the motor. The power switching components extend from a circuit board and are received within recesses of the end cap. The switching components are electrically insulated from the end cap, but are thermally conductive to the end cap within the recesses to dissipate heat during operation. The switching components are preferably disposed in radially equally spaced positions on the circuit board to provide even heat loading to the end cap.

Abstract: A multilayer circuit board system or laminated circuit board system for use in a motor controller includes a motherboard, at least one power substrate circuit board, and a capacitor circuit board. The mother board includes mounting areas for receiving the power substrate board and capacitor circuit board at a 90.degree. angle. The capacitor circuit board, power substrate circuit board, and mother circuit board can be interconnected without the use of external connectors or wires. A fan can be disposed at a front edge of the power substrate circuit boards to provide air flow across their planar surfaces.

Abstract: A method for generating electrical frequencies of a alternating current motor is disclosed wherein a torque current command signal, a d-axis voltage command signal and a d-axis voltage feedback signal are combined to generate the stator electrical frequency in the synchronous reference frame. The method also provides an estimate of the rotor electrical frequency as well as of the motor speed. The frequency generator is preferably incorporated in a variable frequency motor controller for driving a motor at desired speeds independent of changing load conditions. The generator permits the controller to maintain field oriented control without the need for speed sensing and feedback.