Abstract: A system and method for mounting a bearing assembly on a shaft includes an internal flange, external flange, and a sleeve. The internal flange is securable to the bearing assembly and has a displacement pin extending outward that defines an initial position of the bearing assembly relative to the shaft. The external flange is secured to the internal flange via fasteners passing through elongated holes. The external flange has an opening configured to receive the displacement pin. The external flange may be rotated when coupled to the internal flange with the fasteners between a first position where the external flange opening is not in register with the displacement pin and a second position where the external flange opening is in register with the displacement pin. A sleeve has a tapered outside diameter and is engageable with the external flange.

Abstract: A coupling transmits torque between two shafts approximately aligned on a shaft axis. The coupling has a center axis approximately aligned with the shaft axis. The coupling comprises arcuate coupling segments with ends extending generally parallel to the coupling center axis and arcuate portions extending between the ends. The arcuate coupling segments are arranged in a ring with adjacent segments being arranged end to end to form the coupling. Each coupling portion comprises a first clamp ring adapted to be operatively attached to a shaft and a second clamp ring adapted to be operatively connected to another shaft. Elastomer material extends between both clamp rings. The elastomer material extends axially and circumferentially on each clamp ring in areas adjacent to each end of the arcuate coupling segment.

Abstract: A magnetic coupling for transferring rotational motion from a prime mover to a load includes reference marks calibrated to indicate torque applied to the coupling during operation. A light source providing intermittent light flashes permits a user to visibly discern the relative rotational position of the reference marks to one another, and thereby determine the torque applied to the coupling.

Abstract: A method includes: (1) providing a rotor for a line start interior permanent magnet motor wherein the rotor has rotor bars slots extending axially along a length of the rotor configured to receive rotor bar material, and magnet slots extending axially along a length of the rotor configured to receive magnetic material; (2) disposing rotor bar material in the rotor bar slots; (3) arranging a first end member on an axial end of the rotor; (4) disposing magnetic material in the magnet slots; (5) magnetizing the magnetic material; and (6) arranging a second end member on the rotor opposite the first end member. The step of arranging the second end member on the rotor occurs after magnetizing the magnetic material.

Abstract: A method for synchronizing a high inertial load with a line-start synchronous motor involves providing a rotor core with rotor bars being formed of a highly conductive material. In accordance with one aspect of the method, a user is directed to operatively couple a load to the motor and drive the load from start to at least near synchronous speed during steady state operation of the motor with the load coupled thereto. The load has an inertia that is greater than an inertia associated with a load driven by a like motor subjected to an equivalent range of starting current but having rotor bars formed from a conductive material having a conductivity lower than that the highly conductive material.

Abstract: A rotor for an LSIPM comprises a plurality of permanent magnets defining a number of poles (“P”) of the LSIPM, and a plurality of rotor bars spaced about the rotor defining a rotor bar area (“BA”). The rotor bars are formed of a conductive material having an associated conductivity (“?RB”). End members are disposed on axial opposite ends of the rotor core. The end members are in electrical contact with the rotor bars. The end members are formed from a material having an associated conductivity (“?EM”). Each end ring member has a minimum geometric cross sectional area (“ERA”) and outer diameter that generally corresponds to the rotor core outer diameter. The ERA is greater than 0.5 times the rotor bar area per the number of poles (BA/P) times a ratio of the rotor bar material conductivity to the end member material conductivity (?RB/?EM).

Abstract: A mechanical soft-start type coupling is used as an interface between a line start, synchronous motor and a heavy load to enable the synchronous motor to bring the heavy load up to or near synchronous speed. The soft-start coupling effectively isolates the synchronous motor from the load for enough time to enable the synchronous motor to come up to full speed. The soft-start coupling then brings the load up to or near synchronous speed.

Abstract: A coupling transmits torque between two shafts approximately aligned on a shaft axis. The coupling has a center axis approximately aligned with the shaft axis. The coupling comprises arcuate coupling segments with ends extending generally parallel to the coupling center axis and arcuate portions extending between the ends. The arcuate coupling segments are arranged in a ring with adjacent segments being arranged end to end to form the coupling. Each coupling portion comprises a first clamp ring adapted to be operatively attached to a shaft and a second clamp ring adapted to be operatively connected to another shaft. Elastomer material extends between both clamp rings. The elastomer material extends axially and circumferentially on each clamp ring in areas adjacent to each end of the arcuate coupling segment.

Abstract: An electro-dynamic machine has a rotor and stator with a gap therebetween. The machine has a frame defining a hollow interior with end cavities on axially opposite ends of the frame. A gas circulating system has an inlet that supplies high pressure gas to the frame interior and an outlet to collect gas passing therethrough. A liquid coolant circulating system has an inlet that supplies coolant to the frame interior and an outlet that collects coolant passing therethrough. The coolant inlet and gas inlet are generally located on the frame in a manner to allow coolant from the coolant inlet to flow with gas from the gas inlet to the gap. The coolant outlet and gas outlet are generally located on the frame in a manner to allow the coolant to be separated from the gas with the separated coolant and gas collected for circulation through their respective circulating systems.

Abstract: A roller bearing cage has a cage element adapted for retaining the generally cylindrically shaped rollers and allowing the rollers to be rollable therein. The cage element includes a main portion having a plurality of pockets, an outward flange portion extending outwardly in a radial direction and an inward flange portion extending outwardly in the radial direction. The outward flange portion is formed on a side edge of the main portion and the inward flange is formed on an opposite side edge portion thereof. The main portion defines the smallest diameter of the bearing cage and is less than the roller pitch diameter.

Abstract: A primary for a linear drive motor has first and second stacks, each with inner and outer teeth and a bearing mount. A magnet is disposed between the first and second stacks, and a coil wrapped is between the first and second stacks. A bearing is operatively mounted to at least one of the bearing mounts of the first and second stacks. The outer teeth of the first and second stacks may have a projection comprising the bearing mount. The bearing mount may be embedded within the stacks. The stacks may be assembled in a housing and the housing may have a first bearing outboard of the first stack, a second bearing outboard of the second stack, and a third bearing in staggered relationship with the first and second bearings across the housing in an arrangement bilaterally symmetric about an axis transverse to the direction of travel.

Abstract: A roller bearing cage has a cage element adapted for retaining the barrel-shaped rollers and allowing the rollers to be rollable therein. The cage element includes a main portion having a plurality of pockets, an outward flange portion extending outwardly in a radial direction and an inward flange portion extending inwardly in the radial direction. The outward flange portion being formed on a side edge of the main portion and the inward flange being formed on an opposite side edge portion thereof. The outward flange portion includes an outward flange guide surface for guiding barrel-shaped rollers. The guide surface is cylindrical in shape and adjacent each pocket. The guide surface is adapted to abut an axial end of the rollers.

Abstract: A line-start synchronous motor has a housing, a rotor shaft, and an output shaft. A soft-start coupling portion is operatively coupled to the output shaft and the rotor shaft. The soft-start coupling portion is configurable to enable the synchronous motor to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling. The synchronous motor is sufficiently rated to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling.

Abstract: A system and method for mounting a bearing assembly on a shaft includes an internal flange, external flange, and a sleeve. The internal flange is securable to the bearing assembly and has a displacement pin extending outward that defines an initial position of the bearing assembly relative to the shaft. The external flange is secured to the internal flange via fasteners passing through elongated holes. The external flange has an opening configured to receive the displacement pin. The external flange may be rotated when coupled to the internal flange with the fasteners between a first position where the external flange opening is not in register with the displacement pin and a second position where the external flange opening is in register with the displacement pin. A sleeve has a tapered outside diameter and is engageable with the external flange.

Abstract: An electric machine has a stator that comprises a plurality of laminations with teeth and cooling apertures about a central opening. When the laminations are stacked to form the stator core, the teeth of adjacent laminations cooperate to form slots disposed circumferentially about the central opening that are configured to receive a plurality of stator windings, and the cooling apertures angularly spaced about the central opening cooperate to form cooling manifolds that extend along a length of the stator core. A portion of the laminations has their cooling apertures offset from other laminations in the stack in a manner to create a plurality of flow paths transverse to the manifolds. The transverse flow paths extend angularly between laminations and adjacent manifolds. A header assembly directs flow into and out of the stator core.

Abstract: An electric machine has a stator that comprises a plurality of laminations with an outer periphery, and each of the laminations has teeth about a central opening such that when the laminations are stacked side-by side to form the stator core, the plurality of teeth of adjacent laminations cooperate to form slots disposed circumferentially about the central opening that are configured to receive a plurality of stator windings. Each of the laminations has a plurality of cooling apertures angularly spaced about the central opening. The cooling apertures of adjacent laminations cooperate to form cooling manifolds that extend along a length of the stator core. A portion of the laminations has their cooling apertures offset from other laminations in the stack in a manner to create a plurality of flow path transverse to the manifolds and angularly between laminations and adjacent manifolds.

Abstract: A method of constructing a linear drive motor assembly is disclosed. In accordance with the method, a support plate and a platen with a plurality of teeth are provided. A honeycomb core comprising a commercially available, off-the-shelf honeycomb material is provided. The honeycomb core has a plurality of cells arranged in a planar array where the plurality of cells is defined by walls extending in planes substantially perpendicular to the planar array. The support plate is directly secured to one side of the planar array. The platen is secured directly to the other side of the planar array. A forcer having a motor stack is magnetically coupleable to the platen to form a linear drive motor.

Abstract: A secondary for a motor, for instance a linear drive motor, has a sheet of highly magnetic permeable material with a plurality of slots extending through the sheet spaced along a length of the sheet. The slots define a plurality of teeth in the sheet and enable the sheet to be conformable to a mounting surface when forming the secondary of the motor. The top surface of the sheet has a plurality of pockets formed adjacent the plurality of slots. The pockets extend parallel to the width and are spaced along the length of the sheet. The pockets form a sensor operatively connected to a control of the motor. The sensor may be an encoder, and/or the sensor may be operatively connected to a control for controlling commutation of the motor, and/or setting positional limits and/or “home(s)” for the motor, providing absolute positional information and/or providing information about the sheet, for instance, the identity of one platen among many.

Abstract: A primary for a linear drive motor has a stage with stacks made from solid steel. Each stack has inner and outer teeth made that form a generally u-shaped cross-section for the stack. A magnet is disposed between the first and second stacks and a a coil wrapped between the first and second stacks. The stacks may be placed in a housing or may be formed as a housingless stage. The stacks and/or housing may be modified to selectively skew motor alignment to reduce motor cogging. The stacks may be contoured to follow various secondary forms. The stack inner and outer teeth lengths may be adjusted to help balance or optimize the magnetic circuit, to increase tooth surface area for increasing force, to allow more motor windings in the coil of the stack assembly, and to help locate the magnet and coil near the tooth surface.

Abstract: A coupling transmits torque between shafts approximately aligned on a shaft axis. The coupling has a center axis approximately aligned with the shaft axis and a center element formed from an elastomer material. The center element has first and second axial sides. A clamp ring extends axially from each side of the center element along the coupling center axis. The clamp rings may include slots for fasteners for mounting the coupling to shaft hubs. The clamp ring has a flange portion embedded within the center element. Each clamp ring flange portion extends substantially away from the coupling center axis within the center element. An amount of extension away from the coupling center axis is selected to provide the coupling with a desired torsional stiffness characteristic. In accordance with a method, the coupling is formed by selecting the flange portions that will provide the coupling with a desired torsional stiffness characteristic.